Copyright ©
CX460 TIER 3 CRAWLER EXCAVATOR SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION 1
2
3
4
5
6
SECTION N°
REFERENCE N°
GENERAL INFORMATION Safety, general information and standard torque data ..................................... 1001 General specifications and special torque setting ........................................... 1002
7-27691EN SC4601002-0EN
ENGINE Radiator and oil-cooler .................................................................................... 2001 Engine specifications ..............................................................................................* Disassembly and assembly of the engine ..............................................................* FUEL SYSTEM Fuel tank .......................................................................................................... 3001 Fuel engine system ................................................................................................*
SM4603001-0EN
ELECTRICAL SYSTEM Electrical system, electrical and electronic troubleshooting ............................ 4001 Main and engine electronic control boxes ....................................................... 4003
SC4604001-0EN SM4604003-0EN
UNDERCARRIAGE Removal and installation of tracks ................................................................... 5001 Rollers ............................................................................................................ 5003 Sprocket........................................................................................................... 5004 Idler wheel and tension shock absorber .......................................................... 5005
SM160B5001-0EN SM4605003-0EN SM160B5004-0EN SM4605005-0EN
DRIVE TRAIN Drive motor and final drive transmission removal and installation ................... 6001 Swing reduction gear, removal and installation ............................................... 6003 Swing reduction gear, disassembly and assembly .......................................... 6004 Travel reduction gear disassembly and assembly .......................................... 6005
SM4606001-0EN SM4606003-0EN SM4606004-0EN SM4606005-0EN
7
UNDERCARRIAGE HYDRAULICS
8
UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components.............................................. 8000 Specifications, troubleshooting, checks and hydraulic pressure settings ........ 8001 Hydraulic reservoir removal and installation ................................................... 8002 Main and hydraulic pilot pumps, removal and installation .............................. 8003 Main hydraulic control valve, removal and installation .................................... 8004 Attachment cylinders, removal and installation ............................................... 8005 Hydraulic swivel, removal and installation ...................................................... 8006 Pilot blocs, removal and installation................................................................. 8007 Swing motor, removal and installation ............................................................. 8008 Main hydraulic pump, disassembly and assembly ........................................... 8010 Main hydraulic control valve, disassembly and assembly................................ 8011 Attachment cylinders, disassembly and assembly .......................................... 8012 Hand control levers, disassembly and assembly ............................................. 8013 Foot control levers, disassembly and assembly............................................... 8014 Six-solenoid valves, disassembly and assembly ............................................. 8015 Caution valve, disassembly and assembly ...................................................... 8016 Safety valves.................................................................................................... 8017 Hydraulic swivel, disassembly and assembly .................................................. 8018 Swing motor, disassembly and assembly ........................................................ 8019 Hydraulic functions .......................................................................................... 8020 Travel hydraulic motor, disassembly and assembly ......................................... 8021 Fan motor, removal and installation ................................................................. 8022 Fan motor, disassembly and assembly............................................................ 8023 Fan pump, removal, disassembly, assembly and installation........................... 8024 Hydraulic component functions........................................................................ 8030
CNH
SM4602001-0EN
Lep SM460TOC-0EN
SM4608000-0EN SC4608001-0EN SM4608002-0EN SM4608003-0EN SM4608004-0EN SM4608005-0EN SM4608006-0EN SM4608007-0EN SM4608008-0EN SM4608010-0EN SM4608011-0EN SM4608012-0EN SM4608013-0EN SM4608014-0EN SM4608015-0EN SM4608016-0EN SM4608017-0EN SM4608018-0EN SM4608019-0EN SC4608020-0EN SM4608021-0EN SM4608022-0EN SM4608023-0EN SM4608024-0EN SC4608030-0EN Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright ©
DIVISION/SECTION 9
SECTION N°
UPPERSTRUCTURE Upperstructure, turntable and counterweight..................................................... 9002 Boom, dipper and bucket ................................................................................... 9003 Seat, removal and installation............................................................................ 9004 Cab and cab equipment..................................................................................... 9005 Air conditioning unit disassembly and assembly................................................ 9007 Large size hydraulic schematics ......................................................................Pocket Large size electrical schematics ......................................................................Pocket
REFERENCE N° SM4609002-0EN SM4609003-0EN SM4609004-0EN SM4609005-0EN SM4609007-0EN 87574463A 87574470A
* Consult the Engine Service Manual NOTE: CNH Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.
Lep SM460TOC-0EN
Issued 09-07
1001
Copyright ©
Section 1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS
CNH
Lep 7-27691EN
Copyright © 2006 CNH France S.A. Printed in France February 2006
Copyright ©
1001-2
TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
!
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN
Issued 02-06
Copyright ©
1001-3
GENERAL INFORMATION Cleanning
Gears
Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in a suitable cleaning solvent, dry the bearings completely and put oil on the bearings.
Check all gears for wear and damage. Replace gears that have wear or damage.
Inspection Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures.
Bearings Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.
Needle bearings Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
Lep 7-27691EN
Oil seals, O-rings and gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings.
Shafts Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage.
Service parts Always install genuine Case service parts. When ordering refer to the Parts Catalog for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty.
Lubrication Only use the oils and lubricants specified in the Operator’s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty.
Issued 02-06
Copyright ©
1001-4
SAFETY
!
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the keyswitch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags Part Number 331-4614 are available from your service parts supplier
!
WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.
!
WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.
!
WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.
!
WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.
.
!
WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.
!
WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.
!
WARNING: This is a one man machine, no riders allowed.
Lep 7-27691EN
Issued 02-06
Copyright ©
1001-5
!
!
!
!
WARNING: When servicing or repairing the machine, keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times.
!
WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.
!
WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.
!
WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
WARNING: Use insulated gloves or mittens when working with hot parts.
WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service.
WARNING: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
!
WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.
!
WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).
!
WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.
Lep 7-27691EN
Issued 02-06
Copyright ©
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then tighten.
Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size)
M6 [mm]
M8
M10
M12
M14
M16
M18
M20
10
13
17
19
22
24
27
30
[in.]
0.39
0.51
0.67
0.75
0.87
0.95
1.06
1.18
[Nm]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[lb-ft]
5.1
14.5
28.9
43.4
72.3
115.7
144.6
217
[mm]
5
6
8
10
12
14
14
17
[in.]
0.20
0.24
0.32
0.39
0.47
0.55
0.55
0.67
[Nm]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
[lb-ft]
6.5
15.9
31.1
57.9
86.9
130.2
181
253.2
Spanner Cap Screw Tightening torque
Spanner Socket Head Cap Screw
Lep 7-27691EN
Tightening torque
Issued 02-06
1002
Copyright ©
Section 1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS
CNH
Lep SC4601002-0EN
Copyright © 2007 CNH France S.A. Printed in France March 2007
Copyright © 1002-2
TABLE OF CONTENTS
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5 Machine ....................................................................................................................................................................... 5 Engine .......................................................................................................................................................................... 5 Serial numbers of the components .............................................................................................................................. 5 FLUIDS AND LUBRICANTS ............................................................................................................................................ 6 Hydraulic fluid .............................................................................................................................................................. 6 Transmission component oil ........................................................................................................................................ 6 Grease ......................................................................................................................................................................... 6 Engine Oil .................................................................................................................................................................... 7 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8 Anti-freeze/Anti-corrosion........................................................................................................................................... 10 Environment ............................................................................................................................................................... 10 Plastic and resin parts................................................................................................................................................ 10 SPECIFICATIONS ......................................................................................................................................................... 11 Main data ................................................................................................................................................................... 11 Performance .............................................................................................................................................................. 11 Complete machine dimensions .................................................................................................................................. 11 Main body dimensions ............................................................................................................................................... 11 Engine ........................................................................................................................................................................ 12 Cooling system .......................................................................................................................................................... 12 Capacity of coolant and lubricants ............................................................................................................................. 12 Hydraulic oil filter........................................................................................................................................................ 12 Fuel filter .................................................................................................................................................................... 12 Operating devices ...................................................................................................................................................... 13 Hydraulic system........................................................................................................................................................ 14 Swing unit .................................................................................................................................................................. 16 Travel lower body....................................................................................................................................................... 16 Work Unit ................................................................................................................................................................... 17 Digging force (ISO 6015) ........................................................................................................................................... 18 COMPONENT WEIGHT................................................................................................................................................. 19 Major component weight ............................................................................................................................................ 19 Bucket weight............................................................................................................................................................. 20 Other component weight ............................................................................................................................................ 21 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22 Sprocket ..................................................................................................................................................................... 22 Idler wheel.................................................................................................................................................................. 23 Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-3 Upper roller .................................................................................................................................................................24 Lower roller .................................................................................................................................................................25 Track...........................................................................................................................................................................26 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27 1. Boom foot/Frame ....................................................................................................................................................27 2. Boom cylinder foot/Frame.......................................................................................................................................28 3. Boom cylinder head/Boom......................................................................................................................................28 4. Arm cylinder foot/Boom ..........................................................................................................................................29 5. Boom/Arm...............................................................................................................................................................29 6. Arm cylinder head/Arm ...........................................................................................................................................29 7. Bucket cylinder foot/Arm.........................................................................................................................................30 8. Connecting rod/Arm................................................................................................................................................30 9. Compensator/Bucket ..............................................................................................................................................30 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31 11. Arm/Bucket ...........................................................................................................................................................31 SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32 For boom foot .............................................................................................................................................................32 SPECIAL TORQUE SETTINGS......................................................................................................................................33 MACHINE OVERALL DIMENSIONS ..............................................................................................................................36
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-4
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-5
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.
Machine
1 2
3
CT04A171A
(1) Type ....................................................................................................................................................................... (2) Serial number ........................................................................................................................................................ (3) Year of manufacture...............................................................................................................................................
Engine Make and type............................................................................................................................................................. Serial number..............................................................................................................................................................
Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear .................................................................................................................................................. Travel reduction gears ................................................................................................................................................. Control valve ...............................................................................................................................................................
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-6
FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.
!
WARNING: The conditions of use for individual fluids and lubricants must be respected.
Hydraulic fluid CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature. Temperate climates: -20°C to +40°C (-4° to 104° F) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates: 0°C to +50°C (32° to 122° F) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates: -25°C to +20°C (-13° to 68° F) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C (-22° to 104° F) This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit completely before refilling with this fluid. CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-7
Engine Oil THE CASE/AKCELA No. 1 engine oil is recommended for your engine. This oil ensures proper lubrication of your engine for all operating conditions. If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1 2 2 3 3
CT02M001
1) With mineral base (2) With semi-synthetic base (3) With synthetic base
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-8
Engine fuel, maintenance of fuel filters and fuel storage In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine. As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.
Fuel to be applied Selection of fuel Following conditions must be met for the diesel engines, that is the one; 1 In which no dust even fine one is mixed, 2 With proper viscosity, 3 With high cetane rating, 4 With good flow properties in lower temperature, 5 With not much sulfur content, and 6 With less content of carbon residue Applicable standards for diesel fuel Applicable Standard
Recommendation
JIS (Japanese Industrial Standard)
NO.2
DIN (Deutsche Industrie Normen)
DIN 51601
SAE (Society of Automotive Engineers) Based on SAE-J-313C
NO. 2-D
BS (British Standard) Based on BS/2869-197
Class A-1
EN590 If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life. Be sure to observe the following requirements for selecting fuel. Sulfur content............................................................................... 2500 ppm or less HFRR*.......................................................................................... 460 mm or less Water content............................................................................... 0.05 wt% or less * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions. HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-9 If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above. IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited. Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control. IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to fol- low the items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns caused by not to follow these items. 1 Selection of engine oil Use API grade CF-4 or JASO grade DH-1. 2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s Manual. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. * EGR: Exhaust Gas Recircultion
Maintenance of fuel filters Be sure to use the genuine fuel filters. The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment. If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time. IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use of a wrong filter. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Manual. IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. Time to replace filters may be advanced according to properties of the fuel being supplied. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when sup- plying fuel. • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate. • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel. Water drain cock is provided on the bottom side of the fuel tank. • Drain water before starting the engine every morning. • In addition, remove the cover under the tank once a year to clean up inside of the tank.
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-10
Fuel storage Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.
Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.
Environment Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.
Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint solvents etc... Use only water, soap and a soft cloth. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-11
SPECIFICATIONS Main data Model name ............................................................................................................................CX460 Hydraulic Excavator Operating weight ............................................................................................................................. 46600 kg (102735 lbs) Engine output ....................................................................................................................................... 270 kW / 1950 rpm
Performance Swing speed....................................................................................................................................................... 9.0 Tr/min. Travel speed Low Speed.................................................................................................................................... 3.1 km/h (1.93 mph) High Speed ................................................................................................................................... 5.3 km/h (3.30 mph) Maximum drawbar pull ..........................................................................................................................341 kN (76659.85) Grade ability ........................................................................................................................................................70% (35°) Ground pressure ............................................................................................... 80 kPa (600 mm (23.62 in) grouser shoe)
Complete machine dimensions Standard arm (3.40 m) (11 ft 1.85 in)
Short arm (2.55 m) (8 ft 4.39 in)
Length
11940 mm (470.07 in)
11990 mm (472.04 in)
Width
3350 mm (131.88 in)
3350 mm (131.88 in)
Height
3600 mm (141.73 in)
3670 mm (144.48 in)
Main body dimensions Main body width .............................................................................................................. See machine overall dimensions Main body length............................................................................................................. See machine overall dimensions Upper side swing body width ................................................................................................................. 3040 mm (120 in) Cab width ............................................................................................................................................ 1000 mm (39.37 in) Main body height............................................................................................................................... 3270 mm (128.73 in) Tail swing radius ................................................................................................................................ 3620 mm (142.51 in) Distance of rear swing body.............................................................................................................. 3600 mm (171.73 in) Ground clearance for upperstructure ...................................................................................................... 1330 mm (52.36) Center-to-center of wheels.................................................................................................................... 4400 mm (173.22) Overall track length ............................................................................................................................... 5450 mm (214.56) Maximum track width ........................................................................................................................ 3350 mm (131.88 in) Center-to-center for track ...................................................................................................................... 2750 mm (108.26) Width of track shoe .................................................................................600 mm (23.62 in) (Optional: 750 mm (29.52 in) Minimum ground clearance (To bottom of lower frame) ............................................................................ 540 mm (21.25)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-12
Engine Name.............................................................................................................................................................ISUZU, 6UZ1 Type: ................................................................................ Water-cooled, 4-cycle diesel, 6-cylinder in line, direct injection .............................................................(electronic control), turbocharger with air cooled intercooler, without cooling fan. No. of cylinders - bore x stroke....................................................................................................6-dia. 120 mm x 145 mm Displacement........................................................................................................................................ 9.839 L (2.599 gal) Compression ratio ....................................................................................................................................................... 17.5 Rated output.......................................................................................................................................270 kW / 1950 min-1 Maximum torque................................................................................................................. 1435 Nm / apprex. 1500 min-1 Dry weight ........................................................................................................................................Approximately 840 kg Engine dimensions (LxWxH) ........................................................................ 1235x953x1272 mm (48.62x37.51x50.07 in) Oil pan ...................................................................................................................................... All direction 35°, inclinable Cooling fan ................................................... Remote (diameter 1016 mm (39.99 in) suction type-6 blades resin & steel) Oil pan capacity.................................................. Maximum: 36 L (9.51 gal) Minimum: 25 L (6.60 gal) (excluding oil filter) Direction of rotation ...................................................................................................................... Right (as seen from fan) Starter, reduction type ................................................................................................................................... .24 V, 5.5 kW Alternator, AC type ............................................................................................................................................. 24 V, 50 A Battery ............................................................................................................................................... 2 x 12V, 128 Ah/5 Hr
Cooling system Fan drive system .........................................................................................................................................Hydraulic drive Fan type........................................................................................................... Ø 1016 mm (39.99 in), 6 blades, air intake Radiator Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Oil cooler Fin type .................................................................................................................................................................. wavy Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in) Inter-cooler Fin type ...............................................................................................................................................triangular straight Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Fuel cooler Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Capacity of coolant and lubricants Coolant ...................................................................................................................................................... 38 L (10.03 gal) Fuel ....................................................................................................................................................... 611 L (161.41 gal) Lubricant for engine..................................................................................................................................... 36 L (9.51 gal) Lubricant for travel reduction gear (per side)............................................................................................... 15 L (3.96 gal) Lubricant for swing reduction gear (per side) ........................................................................................... 10.5 L (2.77 gal) Hydraulic oil........................................................................................................................................... 460 L (121.51 gal) Capacity of hydraulic oil tank................................................................................................................... 230 L (60.76 gal)
Hydraulic oil filter Suction filter (inside tank) ....................................................................................................................................150 mesh Return filter (inside tank) .......................................................................................................................................... 10 µm Nephron filter (inside housing) ................................................................................................................................... 1 µm Pilot line filter (inside housing).................................................................................................................................. 10 µm
Fuel filter Main filter.................................................................................................................................................................... 4 µm Pre-filter.................................................................................................................................................................... 10 µm
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-13
Operating devices Operator's seat Location: left side Structure: KAB 555: Low frequency air suspension with helical springs and double acting hydraulic damper. Cab Smooth and round shape design cab, fabricated by press work Safety glass for all window. Levers and pedals For travel use: Levers and pedals (hydraulic pilot type) (x2) For operating machine use: Levers (hydraulic pilot type) (x2) Instruments and switches Work mode switchover: 4 modes (heavy digging, standard, finishing and auto) Travel speed switchover: Low-speed / high-speed switch One-touch idle: Knob switch type Monitor device Machine status display (full-dot liquid crystal) Travel speed selection status: Low Speed / High Speed Work mode selection status: H/S/L/A Auto idle selection status: ON/OFF Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge: bar graph indicator Engine coolant temperature gauge: bar graph indicator Hydraulic oil temperature gauge: bar graph indicator Hour meter: digital type Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Over heat* Battery charge* Faulty electrical system* Refill fuel*
Engine oil pressure*
Refill coolant*
Engine preheat
Auto warm-up
Air cleaner
Idling
Service interval
Digging power up
Lighting Working light
House:
24V, 70W (x1)
Boom:
24V, 70W (x1)
Cab:
24V, 70W (x2)
Interior light
24V, 10W (x1)
Horn: electric horn (x2) Other: Wiper with intermittent function. Window washer fluid. Air conditioner. Rear view mirror (left and right side). DC-DC converter.
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-14
Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer............................................................................................................................................... Kawasaki Pump type .............................................................................................. double variable displacement piston pump Displacement volume ................................................................................................. 182 cm3 (11.11 cu in) x 2 /rev Rated operating pressure .......................................................................................................... 31.4 MPa (4554 psi) Maximum operating pressure .................................................................................................... 34.3 MPa (4975 psi) Input revolution speed......................................................................................................1980 min-1 (at 1980 rpm-1) Maximum discharge flow .................................................. 360 L/min (95.10 gpm) x 2 at 1980 min-1 (at 1980 rpm-1) Input horsepower ........................................................................................................................................ 221.6 kW Shaft input horsepower ................................................................................224.7 kW at 1980 min-1 (at 1980 rpm-1) Shaft input torque .............................................................................................. 1072.8 Nm (791 lb-ft) at 1980 min-1 Pilot pump Pump type ............................................................................................................................................... Gear pump Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev Operating pressure ........................................................................................................................ 3.9 MPa (566 psi) Maximum flow ....................................................................... 29.7 L/min (7.84 gpm) (at 1980 min-1) (at 1980 rpm-1) Input horsepower ............................................................................................................................................ 3.1 kW Control characteristics Simultaneous output control of overall. Negative control. Electric horse power control. Control Valve Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Operation method: hydraulic pilot method: travel, swing and operating machine Maximum flow .......................................................................................................................... 360 L / min (95.10 gpm) Main relief set pressure.......................................................standard; 31.4 MPa (4554 psi) (at 340 L/min (89.81 gpm)) ...................................................................................... power boost; 34.3 MPa (4975 psi) (at 315 L/min (83.21 gpm)) Overload set pressure.............................................. when boom down; 24.5 MPa (3553 psi) (at 20 L/min (5.28 gpm)) ..................................................................................................... other: 36.3 MPa (5265 psi) (at 20 L/min (5.28 gpm)) Foot relief set pressure ......................................................................3.38 MPa (490.22 psi) (at 61 L/min (16.11 gpm)) Functions Straight travel circuit Boom up / 2-speed internal confluence for arm Boom/Arm load holding circuit Boom down regenerative circuit Arm in forced regenerative circuit Boom up override variable throttle valve Swing priority variable throttle valve Backup 2-speed confluence Hydraulic Cylinders Boom cylinder (x2) Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in) Rod diametre .............................................................................................................................Ø115 mm (Ø4.52 in) Maximum retracted length .......................................................................................................... 2230 mm (87.79 in) Stroke ......................................................................................................................................... 1550 mm (61.02 in) Arm (dipper) cylinder Cylinder bore .............................................................................................................................Ø200 mm (Ø7.87 in) Rod diametre .............................................................................................................................Ø140 mm (Ø5.51 in) Maximum retracted length ........................................................................................................ 2588 mm (101.88 in) Stroke ......................................................................................................................................... 1820 mm (71.65 in) Bucket cylinder Cylinder bore .............................................................................................................................Ø165 mm (Ø6.49 in) Rod diametre .............................................................................................................................Ø115 mm (Ø4.52 in) Maximum retracted length .......................................................................................................... 1972 mm (77.63 in) Stroke ......................................................................................................................................... 1285 mm (50.59 in)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-15 Rotating Joint Operating pressure High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi) Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi) Pilot port (P) .................................................................................................................................. 3.9 MPa (566 psi) Hydrostatic test pressure High pressure passage (ABCD) ................................................................................................ 51.5 MPa (7469 psi) Drain port (T) ................................................................................................................................. 2.0 MPa (290 psi) Pilot port (P) .................................................................................................................................. 5.9 MPa (856 psi) Flow High pressure passage (ABCD) .......................................................................................... 360 L / min (95.10 gpm) Drain port (T) ......................................................................................................................... 40 L / min (10.56 gpm) Pilot port (P) ............................................................................................................................ 31 L / min (8.18 gpm) Number of revolutions...................................................................................................................... 15 min-1 (15 rpm-1) Torque; when pressurizing 2 ports..................................................................................................196 Nm (144.5 lb-ft) Port A; forward right ...................................................................................................................................................G1 Port B; forward left .....................................................................................................................................................G1 Port C; backward right ...............................................................................................................................................G1 Port D; backward left..................................................................................................................................................G1 Port E; drain port ....................................................................................................................................................G1/2 Port F; pilot port ..................................................................................................................................................... G1/4 Solenoid Valve Valve specifications Maximum flow...................................................................... P -> B: 20 L/min (5.28 gpm) Other: 5 L/min (1.32 gpm) Rated pressure ......................................................................................................................... 4.5 MPa (652.67 psi) Solenoid specifications Operating voltage ................................................................................................................................ DC 20 to 32 V Power consumption .................................................................................................................................. 17 W max. Hand control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi) Operating angle Ports 1, 3 .............................................................................................................................................................. 19° Ports 2, 4 .............................................................................................................................................................. 25° Operating torque Port 1 ...................................................................................................................0.58 to 2.03 Nm (0.42 to 1.49 lb-ft) Port 3 ...................................................................................................................0.47 to 1.92 Nm (0.34 to 1.41 lb-ft) Ports 2, 4 .............................................................................................................0.71.to 2.30 Nm (0.52 to 1.69 lb-ft) Foot control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi) Operating angle ..................................................................................................................................................... 12.4° Operating torque Valve................................................................................................................. 4.16 to 9.03 Nm (3.068 to 6.660 psi) Damper.........................................................................................4.90 Nm (at 0.0275 m/s) (3.614 psi (at 0.090 f/s))
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-16
Swing unit Swing circle ......................................................................................................... Swing bearing type (with internal gears) Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type) Swing lock .............................................................................................. Mechanical lock (swing lock switch linkage type) Swing hydraulic motor .....................................................................................................Fixed displacement piston motor Displacement ......................................................................................................................... 250 cm3 (15.26 cu in)/rev Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi) Operating flow ............................................................................................................................. 360 L/min(95.10 gpm) Mechanical brake torque.....................................................................................................1288 Nm (949.97 lb-ft) min. Brake off pressure................................................................................................................ 2.9 MPa (420.60 psi) max. Relief valve set pressure....................................................................................................... 29.3 MPa (4249 psi) max. Reduction gear .................................................................................................. Planetary gear 2-stage reduction System Reduction ratio ........................................................................................................................................................ 27.143
Travel lower body Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake Displacement .............................................................................................. 290.7/170.1 cm3 (17.74/10.38 cu in)/rev Operating pressure .................................................................................................................... 34.3 MPa (5192 psi) Operating flow..................................................................................................................... 360.4 L/min (95.20 gpm) Brake torque................................................................................ 71 KNm (52366 Ib-ft) min. (including reduction gear) Relief valve set pressure ............................................35.8 to 38.8 MPa (at 50L/min) (5192 to 5627 psi (at 13.20 gpm) Automatic 2-speed switch-over pressure ....................................................................................... 26.5 MPa (3843 psi) Reduction gear ...................................................................................................Planetary gear 3-stage reduction system Reduction ratio .................................................................................................................................................... 60.652 Travel brake .................................................................................................................................................. Hydraulic lock Parking brake ................................................................................................... Mechanical lock (travel lever linkage type) Track shoe Model ....................................................................................................................... Assembly-type triple grouser shoe Number of shoes (per side)........................................................................................................................................ 50 Shoe width Standard ....................................................................................................................................... 600 mm (23.62 in) Optional ....................................................................................................................................... 750 mm (29.52 in) Grouser height ...................................................................................................................................... 36 mm (1.41 in) Link pitch .......................................................................................................................................... 228.6 mm (8.99 in) Roller Number of upper rollers (per side) ............................................................................................................................... 2 Number of lower rollers (per side)................................................................................................................................ 9 Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-17
Work Unit Model ................................................................................................................................................. Backhoe attachment Capacity / dimensions / working dimensions Bucket width.................................................................................................... 1400 mm (55.11 in) (without side cutter) Width of bucket with side cutter ....................................................................................................... 1510 mm (5944 in) Weight of bucket with side cutter ......................................................................................................1830 kg (4034 lbs) Boom 6980 mm (274.80 in)
Arm (dipper) length
Standard arm
Short arm
3380 mm (133.07 in)
2530 mm (99.60 in) 1840 mm 72.44 in
Bucket radius Bucket wrist angle
176°
Maximum digging radius
12000 mm 472.43 in
11230 mm 442.12 in
Maximum digging radius at ground line
11770 mm 463.38 in
10990 mm 432.67 in
Maximum digging depth
7720 mm 303.93 in
6870 mm 270.47 in
Maximum vertical straight wall digging depth
6570 mm 258.66 in
5670 mm 223.22 in
Maximum reach height
11140 mm 438.58 in
10820 mm 425.98 in
Maximum dump height
7740 mm 304.72 in
7420 mm 292.12 in
Minimum swing radius at front
4990 mm 196.45 in
5140 mm 202.36 in
Overall height with minimum swing radius at front
9250 mm 364.17 in
9320 mm 366.92 in
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-18
Digging force (ISO 6015) Arm (dipper) 3380 mm (133.07 in)
2530 mm (99.60 in)
Bucket digging force (standard)
247 kN (55527.8 lbf)
247 kN (55527.8 lbf)
Bucket digging force (power boost)
270 kN (60698.4 lbf)
270 KN (60698.4 lbf)
209 kN (46985 lbf)
257 kN (57775.9 lbf)
229 kN (51481.2 lbf)
281 kN (63171.3 lbf)
Arm (dipper) digging force (standard) Arm (dipper) digging force (power boost)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-19
COMPONENT WEIGHT Major component weight B
A C
E
D
F
G H
330.3.01.00.51A
Weight information is approximate A) Operating weight .................................................................................................................... 46600 kg (102735 lbs) B) Upper mechanism (including counterweight and turntable bearing) ........................................ 19700 kg (43431 lbs) C) Counterweight............................................................................................................................ 9200 kg (20282 lbs) D) Lower mechanism (with standard grouser shoe) .....................................................................16700 kg (36817 lbs) E) Main Unit Weighty ....................................................................................................................36400 kg (80248 lbs) F) Attachments .............................................................................................................................10000 kg (22046 lbs) G) Boom (including cylinders)......................................................................................................... 5540 kg (12213 lbs) H) Arm (dipper) (including cylinders and linkage).............................................................................2670 kg (5886 lbs)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-20
Bucket weight Bucket capacity (m3)
Weight kg (lbs)
L1 mm (in)
L2 mm (in)
1
1.8
1430 (3153)
1384 (54.48)
1515 (59.64)
2
1.8 HD
1810 (3990)
1400 (55.11)
1508 (59.36)
3
2.0
1500 (3307)
1514 (59.60)
1645 (64.76)
4
2.0 HD
1910 (4211)
1530 (60.23)
1638 (64.48)
5
2.2
1510 (3329)
1825 (71.85)
1956 (77.00)
L1 L2
330.3.01.00.51BA
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-21
Other component weight Engine .....................................................................................................................................................840 kg (1852 lbs) Air cleaner ...............................................................................................................................................17.6 kg (38.8 lbs) Hydraulic pump ......................................................................................................................................... 245 kg (540 lbs) Attachment control valve ........................................................................................................................... 424 kg (935 lbs) Swing motor (excluding pinion) ...............................................................................................................565 kg (1245 lbs) Travel motor and reduction gear assembly .............................................................................................613 kg (1351 lbs) Rotary joint..................................................................................................................................................56 kg (123 lbs) Solenoid valve bank .................................................................................................................................. 7.0 kg (15.4 lbs) Hand control valve ......................................................................................................................................1.9 kg (4.2 lbs) Foot control valve ...................................................................................................................................... 7.8 kg (17.2 lbs) Standard boom......................................................................................................................................3540 kg (7804 lbs) Standard arm (dipper)...........................................................................................................................1690 kg (3726 lbs) Short arm (dipper).................................................................................................................................1490 kg (3285 lbs) Boom cylinder (one) .................................................................................................................................. 400 kg (882 lbs) Arm (dipper) cylinder...............................................................................................................................695 kg (1532 lbs) Bucket cylinder .......................................................................................................................................... 390 kg (860 lbs) Fuel tank ................................................................................................................................................... 243 kg (536 lbs) Hydraulic oil tank....................................................................................................................................... 229 kg (505 lbs) Turntable bearing ....................................................................................................................................656 kg (1446 lbs) Muffler ........................................................................................................................................................... 20 kg (44 lbs) Radiator total weight ................................................................................................................................. 208 kg (458 lbs) Oil cooler................................................................................................................................................... 34 kg (75 lbs) Radiator ..............................................................................................................................................23.3 kg (51.3 lbs) Air cooler................................................................................................................................................ 28.8 kg (63 lbs) Fuel cooler ............................................................................................................................................ 1.2 kg (2.64 lbs) Idler wheel................................................................................................................................................. 251 kg (553 lbs) Upper roller ................................................................................................................................................... 44 kg (97 lbs) Lower roller .................................................................................................................................................82 kg (181 lbs) Recoil spring ............................................................................................................................................. 343 kg (756 lbs) Recoil spring ...................................................................................................................................... 141 kg (310.8 lbs) Grease cylinder assembly ................................................................................................................ 62.3 kg (137.3 lbs) Threaded ..........................................................................................................................................68.8 kg (151.6 lbs) Yoke ..................................................................................................................................................66.8 kg (147.2 lbs) Track chains (per side) 600 mm (23.62 in).............................................................................................................................2580 kg (5688 lbs) 750 mm (29.52 in).............................................................................................................................2930 kg (6459 lbs)
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-22
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions P
a
e
Øb
Ød
Øc
800.6.10.00.11A1
Dimension
Mark a Øb Øc Ød e P
Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit
mm
in
90 78 773.6 761.6 867.5 854.5 847.3 43.5 48.5 229 -
3.54 3.07 30.45 29.98 34.15 33.64 33.35 1.71 1.90 9.01 -
Gauge Unit in mm
300 228.6 44.8 5.4
3 .1
117.8
99.6
37.9
R 3∼ 6
R 95 .6 R 36 .9
R 50 .7
24.5
90°
° 40.2
87.6
°
7 23. R4 .8 33 R4 CI01N501
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-23
Idler wheel Dimensions c
Dimension mm in
Mark Standard Limit Standard b Limit Standard c Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit Standard e (bushing) Limit Standard f Limit
b
676 665 22.5 102 92 95 94 95 96 100 99 15 -
a
Øa
e d
f
26.61 26.18 0.88 1.00 4.01 3.62 3.74 3.70 3.74 3.77 3.93 3.89 0.59 -
330.6.10.00.12B
Gauge Unit in mm
250 204
22.5 15
R3
R5
R50
R3
° 10
80
42.5
102
0.2
CI01N502
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-24
Upper roller Dimensions c
Dimension mm in
b
Mark Standard Limit Standard b Limit Standard c Limit Standard Ø d shaft Limit Standard Ø d bushing Limit Standard e bushing Limit Standard f Limit Standard g Limit
150 140 15 104 65 64 65 66 150 149 9 8.5 30 -
a
d
Øa
g
e f 000.6.10.00.8C
5.90 5.51 0.59 4.09 2.55 2.51 2.55 2.59 5.90 5.86 0.35 0.33 1.18 -
Gauge Unit in mm
210
5
104 97
R3
R3
R3
15
65
35
° .1 13
R3
15
R3
125
120 245
CI01N503
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-25
Lower roller Dimensions d
g
b
e
a
f
000.6.10.00.08D
Dimension mm in
Mark Øa b d Ø e (Shaft)
Standard Limit Standard Limit Standard Limit Standard Limit
200 188 25 20 223 233 85 84
7.87 7.40 0.98 0.78 8.77 9.17 3.34 3.30
Dimension mm in
Mark Ø e (bushing) Øf g
Standard Limit Standard Limit Standard Limit
85 86 93 92 24.5 23.9
3.34 3.38 3.66 3.62 0.96 0.94
Gauge Unit in mm
KTA1107X-C02
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-26
Track
c’
c d
d’
e
e’
f
f
f’ (4 pieces)
b
a 800-6-10-00-11E-1
Mark Standard Limit Standard b Limit Standard Ø c (bushing) Limit Standard Ø d (bushing) Limit Standard Ø e (Pin) Limit Standard f Limit
a
Lep SC4601002-0EN
Dimension mm in 52 32 129 121 73.33 68.23 49.2 51.7 48.6 45.1 228.6 -
2.04 1.25 5.07 4.76 2.88 2.68 1.93 2.03 1.91 1.77 8.99 -
Mark Standard Limit Standard Ø d’ (bushing) Limit Standard Ø e’ (Pin) Limit Standard f’ (4 pieces) Limit
Ø c’ (bushing)
Dimension mm in 73.33 68.23 49.2 51.7 48.8 44.9 914.4 -
2.88 2.68 1.93 2.03 1.92 1.76 35.99 -
Issued 03-07
Copyright © 1002-27
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS 4 6 7 1 10 9 3
5 2 8 11 CRIL06C002F
1. Boom foot/Frame a b
d
c
e
330.6.10.00.12C1
Dimension mm in
Mark a (frame) b (boom) c (clearance) Ø d (shaft) Ø e (bushing)
Lep SC4601002-0EN
Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit
874 34.40 882 34.72 871 34.29 868 34.17 3.5 to 5.5 0.13 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78
Issued 03-07
Copyright © 1002-28
2. Boom cylinder foot/Frame a b
e
c
d
330.6.10.00.1.12C2
Dimension mm in
Mark a (boom) b (cylinder) c (clearance) Ø d (shaft) Ø e (bushing)
Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit
126 4.96 132 5.19 125 4.92 122 4.80 1.5 to 3.5 0.05 to 0.13 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78
3. Boom cylinder head/Boom a c
d
330.6.10.00.12D1
Dimension
Mark a (boom) a (cylinder) c (clearance) Ø d (shaft) Ø d (bushing)
Lep SC4601002-0EN
mm Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit
in
140 5.51 137 5.39 679 26.73 675 26.57 1.5 to 3.0 0.05 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78
Issued 03-07
Copyright © 1002-29
4. Arm cylinder foot/Boom a
Mark
b
Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit
c
e
a (boom)
d
Dimension mm in 156 6.14 162 6.37 155 6.10 153 6.02 1.0 to 3.0 0.03 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78
330.6.10.00.12D2
5. Boom/Arm g
a b
g
Mark
c
e
d
330.6.10.00.12E1
Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit Standard g Limit
a (boom)
Dimension mm in 437 17.20 440 17.32 432.7 17.03 429.7 16.91 4.5 to 5.5 0.17 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78 98 3.85 96 3.77
6. Arm cylinder head/Arm a b
e
Mark Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit
c
a (arm)
d
Dimension mm in 156 6.14 161 6.33 155 6.10 153 6.02 1.0 to 3.0 0.039 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78
330.6.10.00.12F1
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-30
7. Bucket cylinder foot/Arm a
Mark
b
e
Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit
a (arm)
c
d
330.6.10.00.12F2
Dimension mm in 141 5.55 146 5.74 140 5.51 138 5.43 1.0 to 3.0 0.039 to 0.11 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38
8. Connecting rod/Arm c
Mark
a
Standard Limit Standard b Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit
a
b
e a d
Dimension mm in 50 1.96 47 1.85 441 17.36 437 17.20 1.5 to 2.0 0.059 to 0.078 Shim adjustment 95 3.74 94 3.70 95 3.74 96.5 3.79
330.6.10.00.12G1
9. Compensator/Bucket c
Mark Standard Limit Standard b (link) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit
a (bucket)
b a e
d
Dimension mm in 480 18.89 485 19.09 479 18.85 476 18.74 1.5 to 3.5 0.059 to 0.13 Shim adjustment 100 3.93 99 3.89 100 3.93 101.5 3.99
330.6.10.00.12G2
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-31
10. Connecting rod/Compensator/Bucket cylinder head c
Mark
a f d e
i
Standard Limit Standard b Limit Standard c (clearance) Limit Standard d (link) Limit Standard e (cylinder) Limit Standard f (clearance) Limit Standard Ø g (shaft) Limit Standard Ø h (bushing) Limit Standard Ø i (bushing) Limit
a
b
h a
g 330.6.10.00.12H1
Dimension mm in 50 1.96 48 1.88 441 17.36 436 17.16 1.5 to 2.5 0.059 to 0.098 Shim adjustment 141 5.55 143 5.62 140 5.51 138 5.43 1.5 to 2.0 0.059 to 0.078 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38 110 4.33 111.5 4.38
11. Arm/Bucket c d
Mark
g Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard d Limit Standard Ø e (shaft) Limit Standard Ø f (bushing) Limit Standard Ø g (bushing) Limit
a (bucket)
f a b
e
Dimension mm in 480 18.89 479 18.85 476 18.74 1.5 to 4.0 0.059 to 0.15 Shim adjustment 16 0.62 10 0.39 100 3.93 99 3.89 100 3.93 101.5 3.99 100 3.93 101.5 3.99
330.6.10.00.12I1
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-32
SHIMS FOR ADJUSTING ATTACHMENT GAPS For boom foot
R O.D I.D
H
000-6-10-02-02A
Part No.
I.D.
O.D.
R
H
Shim Thickness
Material
KNV1132
76
160
100
30
1.2
SPHC
KRV2390
91
190
115
30
1.2
SPHC
KBV1441
101
220
130
30
1.2
SPHC
KBV1748
101
230
135
30
1.2
SPHC
KSV1805
111
240
140
30
1.2
SPHC
R O.D
I.D
H
000-6-10-02-02B
Part No.
I.D.
O.D.
R
H
Shim Thickness
Material
KSV1930
111
240
140
30
1.0
Urethone
KSV11380
111
240
140
30
2.0
Urethone
KSV1931
116
240
140
30
1.0
Urethone
KSV11390
116
240
140
30
2.0
Urethone
KTV10730
121
245
150
50
2.0
Urethone
KTV10740
121
245
150
50
1.0
Urethone
KTV10750
121
260
150
50
2.0
Urethone
KTV10760
121
260
150
50
1.0
Urethone
KWV0097
141
280
160
50
1.0
Urethone
KWV10510
141
280
160
50
2.0
Urethone
KWV0096
141
300
180
50
1.0
Urethone
KWV10500
141
300
180
50
2.0
Urethone
KUV10150
141
300
170
30
1.0
Urethone
KUV10160
141
300
170
30
2.0
Urethone
KUV10130
151
300
170
30
1.0
Urethone
KUV10140
151
300
170
30
2.0
Urethone
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-33
SPECIAL TORQUE SETTINGS No. 1*
Component Travel motor and reduction gear assembly
Screw
Wrench (mm)
M24
36
Torque setting 900-1052 Nm (664-776 lb-ft)
2*
Drive sprocket
M24
36
900-1052 Nm (664-776 lb-ft)
3*
Take-up Roller
M16
24
267-312 Nm (197-230 lb-ft)
4*
Upper roller
M24
36
521-608 Nm (385-448 lb-ft)
5*
Lower roller
M24
36
902-1049 Nm (665-774 lb-ft)
6*
Track guard
M24
36
902-1049 Nm (665-774 lb-ft)
7
Shoe bolt
M24
32
1236-1510 Nm (912-1114 lb-ft)
8
Counterweight
M30
46
1765-2010 Nm (1302-1482 lb-ft)
9*
Turntable bearing
M24
36
952-1050 Nm (702-774 lb-ft)
10 *
Swing equipement
11 * 12 *
Engine
13 * 14 *
M24
36
900-1050 Nm (664-774 lb-ft)
Mount
M20
30
324-373 Nm (239-275 lb-ft)
Front bracket
M10
17
64-73 Nm (47-54 lb-ft)
Rear bracket
M16
24
147-176 Nm (108-130 lb-ft)
Radiator
M16
24
147-176 Nm (108-130 lb-ft)
Frange
M12
19
88-108 Nm (65-79 lb-ft)
Pump
M20
17
367-496 Nm (271-366 lb-ft)
15 * 16 *
Hydraulic pump
17 *
Hydraulic reservoir
M16
24
226-265 Nm (167-195 lb-ft)
18 *
Fuel reservoir
M16
24
226-265 Nm (167-195 lb-ft)
19 *
Control valve
M20
30
333-392 Nm (245-289 lb-ft)
Lock bar
M16
24
267-312 Nm (197-230 lb-ft)
Joint
M12
19
54-64 Nm (40-47 lb-ft)
20 * 21 * 22 23 * 24
Rotating joint Cab Battery
Floor
M16
24
78-80 Nm (57-59 lb-ft)
Mount
M10
17
35-42 Nm (26-31 lb-ft)
M10
17
20-29 Nm (15-21 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-34
19
15, 16
17
11, 12, 13
10 18
8
14 24 7
20, 21
1, 2 9
5 22, 23 4
6
3
1
2
6
7 4 5
6
3
TORQUE_1
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-35
10
9
15
9
14
12
11
16
13
19
18
17 20
22 24
21
23
TORQUE_2
Lep SC4601002-0EN
Issued 03-07
Copyright © 1002-36
MACHINE OVERALL DIMENSIONS NOTE: Numbers are subject to change without notice due to design change or other reasons. The figures give values that include the shoe lug height (36 mm (1.41 in))
Standard arm (3380 mm (133.07 in)) * : with catwalks - (option) * BKTU6001_338M
Short arm (2530 mm (99.60 in)) * : with catwalks - (option) * BKTU6001_253M
Lep SC4601002-0EN
Issued 03-07
2001
Copyright ©
Section 2001 FUEL-COOLER, ENGINE INTER-COOLER, RADIATOR AND OIL-COOLER
CNH
Lep SM4602001-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 2001-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER ............................................................................. 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 3 ENGINE .......................................................................................................................................................................... 4 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 4 ENGINE AND RADIATOR - FIGURE 1 .......................................................................................................................... 6
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS See Section 1002
Lep SM4602001-0EN
Issued 09-07
Copyright © 2001-3
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER Before carrying out any operation on the machine, perform the following operations in the order shown: -
Park the machine on hard, flat ground. Lower the attachment to the ground. Shut down the engine. Remove the starter switch key. Make sure that pressure in the hydraulic system has been completely released (see Operator’s Manual).
!
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the machine to cool down before starting any servicing operation.
Removal
Installation
NOTE: For the removal refer to the figure 1, page 6.
NOTE: For the installation refer to the figure 1, page 6, proceed in the reverse order from that of removal.
STEP 1 Drain the cooling system (see Operator’s Manual).
STEP 2 Release pressure in the hydraulic reservoir to allow the vacuum pump to be mounted (see Section 8000).
1) Coat the thread of reference (37) and (13) with loctite or equivalent after removing any oil film and fasten by tightening torque . 2) Apply packing liquid (69) to the connection of radiator hose after removing any oil film and fasten by tightening torque. 3) Tighten up the hose band from the direction schown on the D.W.G. Before operating the machine: - Check the oil level in the hydraulic reservoir. Top up if necessary. - Check the hydraulic fluid cooling circuit for leaks. - Fill and bleed the engine cooling system (see Operator’s Manual). - Check the engine cooling system for leaks.
Lep SM4602001-0EN
Issued 09-07
Copyright © 2001-4
ENGINE Removal
STEP 7
NOTE: For the removal refer to the figure 1, page 6.
Remove the engine retaining hardware.
STEP 1
NOTE: When installing, make a visual inspection of the condition of the rubber flexible mountings and change them if necessary. Tighten the engine retaining screws to the torque specified in Section 1002.
STEP 8 When there is nothing interfering with the removal of the engine, raise the engine carefully and install it on a suitable repair bench.
STEP 9 Refer to Section 8003 and remove the hydraulic pump.
Installation JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 3
NOTE: For the installation refer to the figure 1, page 6, proceed in the reverse order from that of removal. 1) Coat the thread of reference (11), (35), (37), (41), (43) and (49) with loctite or equivalent after removing any oil film and fasten by tightening torque . 2) The elastic rubbers of reference (46) and (74) should be assembled after confirming the discrimination color. Before operating the machine, carry out the following operations: - Bleed and prime the fuel system (see Operator’s Manual). - Fill and bleed the engine cooling system (see Operator’s Manual). - Check the hydraulic, fuel and cooling systems for leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.
1
CT07A009
Disconnect the earth cable (-) (1) from the battery.
STEP 4 Label and disconnect all the electrical connections from the engine.
STEP 5 NOTE: For the removal refer to the figure 1, page 6. Remove all the clips, etc. which attach the electrical harnesses to the engine and move out of the way.
STEP 6 Install a suitable lifting device on the engine lifting rings (for the weight of the engine, see Section 1002).
Lep SM4602001-0EN
Issued 09-07
Copyright ©
2001-5
NOTES ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... Lep SM4602001-0EN
Issued 09-07
Copyright © 2001-6
ENGINE AND RADIATOR - FIGURE 1
J
J
K
330-5-02-02-24
Lep SM4602001-0EN
Issued 09-07
Copyright © 2001-7 1 - SPL BOLT 2 - BUCKET 3 - ELBOW 4 - HYDRAULIC HOSE 5 - HYDRAULIC HOSE 6 - ELBOW 7 - GEAR PUMP 8 - HIGH STRENGTH BOLT 9 - HIGH STRENGTH WASHER 10 - BRACKET; MUFFLER 11 - HIGH STRENGTH BOLT 12 - HIGH STRENGTH WASHER 13 - BOND 14 - NUT; FLANGED 15 - BOLT; U 16 - MUFFLER 20 - SEAL CLAMP 22 - EXHAUST PIPE 24 - PLUG 25 - HOSE ADAPTER 26 - HOSE CLAMP 27 - AIR HOSE 28 - HOSE CLAMP 30 - BRACKET 31 - AIR-INLET PIPE 32 - BRACKET 33 - AIR HOSE 34 - AIR-INLET PIPE 35 - HIGH STRENGTH BOLT 36 - HIGH STRENGTH WASHER 37 - SEMS BOLT 38 - RADIATOR STAY 39 - HOSE BAND 40 - TUBE 41 - SEMS BOLT 42 - ENGINE SUPPORT REAR 43 - HIGH STRENGTH BOLT 44 - HIGH STRENGTH WASHER 45 - PLATE 46 - ELASTIC RUBBER 47 - SPL NUT 48 - SEMS BOLT 49 - ENGINE SUPPORT REAR 50 - HOSE BAND 51 - VINYL HOSE 52 - HOLDER 53 - SEMS BOLT 54 - RESERVE TANK 55 - BRACKET 56 - VACUUM SENSOR
Lep SM4602001-0EN
57 - ELBOW 58 - SPL JOINT 59 - HIGH STRENGTH NUT 60 - RUBBER HOSE 61 - ELBOW 62 - JUBILEE CLIP 63 - JUBILEE CLIP 64 - AIR-INLET HOSE 65 - ELBOW 66 - CLAMP 67 - SPL BOLT 68 - HOSE CLAMP 69 - LIQUID PACKING 70 - RADIATOR HOSE 71 - CLAMP 72 - BRACKET 73 - ENGINE SUPPORT FRONT 74 - ELASTIC RUBBER 75 - HYDRAULIC HOSE 76 - HYDRAULIC HOSE 77 - HYDRAULIC HOSE 78 - ENGINE SUPPORT FRONT 79 - BRACKET 80 - HOSE BAND 81 - BRACKET 82 - RADIATOR (STD) ASSY 83 - SPL LABEL 84 - AIR CLEANER 85 - AIR HOSE 86 - HARNESS BAND 87 - JUBILEE CLIP 88 - CLAMP 89 - ELBOW 90 - DIESEL ENGINE 91 - BRACKET 92 - HIGH STRENGTH BOLT 93 - HOSE CLAMP 94 - AIR HOSE 95 - HOSE CLAMP 96 - RADIATOR HOSE (IN) 97 - AIR-INLET PIPE 98 - RADIATOR STAY REAR 99 - HIGH STRENGTH BOLT 100 - HIGH STRENGTH BOLT 102 - BRACKET 103 - HOSE CLAMP 104 - CLAMP 105 - LIQUID PACKING 106 - BRACKET 107 - SEMS BOLT 108 - ENGINE; DIESEL 109 - SEMS BOLT 110 - HOSE CLAMP 111 - HIGH STRENGTH BOLT
Issued 09-07
Copyright © 2001-8
NOTES ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................
Lep SM4602001-0EN
Issued 09-07
3001
Copyright ©
Section 3001 REMOVAL AND INSTALLATION OF THE FUEL TANK
CNH
Lep SM4603001-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 3001-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 FUEL TANK .................................................................................................................................................................... 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 4 Description ................................................................................................................................................................. 5
SPECIFICATIONS See Section 1002.
Lep SM4603001-0EN
Issued 09-07
Copyright © 3001-3
FUEL TANK Removal STEP 1
STEP 9 Remove the screws (8) and the protective plate (9).
STEP 10 Remove the screws (21) and the protective plate (22).
STEP 11 Loosen the two screws (10) located under the machine. Open the side portion of the machine and remove the two screws (11) located on the RH side of the fuel reservoir (1). Remove the protective plate (12) of the reservoir. JS00163A1
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 12 Attach labels on the hoses. Remove the hoses and the retaining clips.
STEP 13
STEP 3
Shift the plastic protection (13) from the fuel sensor (14). Remove the retaining screws (15) then the fuel sensor (14) as well as the seal (16).
Turn the ignition key to "ON" without starting the engine.
STEP 14
STEP 4
Remove the screws (17) and (20) from the fuel tank (1), and the shims (18).
Attach a "DO NOT OPERATE" tag to the ignition key in the cab.
STEP 15
STEP 5
Remove the fuel tank (1) using a hoist.
NOTE: The numbers within brackets refer to the figures on pages 5 and 6. Remove the access panel under the fuel reservoir (1).
STEP 6 Open the filling plug (2) of the tank (1). Bleed the remaining fuel using the valve (3) then remove the latter. Remove the filter (19) and the fuel gauge.
STEP 7 Lift the hood of the front boot. Remove the retaining screw (4) of the access ramp (5). Remove the access ramp (5).
STEP 8 Remove the screws (6) on top and then inside the front boot, then remove the protective housing (7).
Lep SM4603001-0EN
Issued 09-07
Copyright © 3001-4
Installation NOTE: The numbers within brackets refer to the figures on pages 5 and 6.
STEP 1 Using a hoist, position the fuel reservoir (1) on the machine.
STEP 2 Install the shims (18) as well as the screws (17) and (20), tighten the screws (17) to a torque of 225.6 to 264.8 Nm (166.39 to 195.31 lbf-ft). Install the valve (3) and tighten the valve (3) to a torque of 14.7 Nm (10.80 lbf-ft).
STEP 8 Install the protective housing (7) on top of the front boot using the screws (6) then put back the screw mask.
STEP 9 Install the access ramp (5) using screws (4). Close the front boot.
STEP 10 Fill the fuel reservoir (see the operator's manual) and make sure that there are no leaks.
STEP 3
STEP 11
Install a new seal (16), then the fuel probe (14) using the five screws (15), reposition the plastic protection correctly (13).
Reinstall the protective plate on top of the machine.
STEP 4 Install the hoses by taking help of the labels attached during removal. Tighten using retaining clips.
STEP 5 Install the reservoir protection (12) using screws (10) and (11). Tighten the screws (10) and (11).
STEP 6 Install the protective plate (9). Tighten the screws (8).
STEP 7 Install the protective plate (22). Tighten the screws (21).
Lep SM4603001-0EN
Issued 09-07
Copyright © 3001-5
Description Location 6
7
9
11
8
6
12
5 11
10
21 22
4
20
4 5 6 7 8 9 10 11 12 20 21 22
SCREW ACCESS RAMP SCREW PROTECTIVE HOUSING SCREW SKID PLATE SCREW SCREW SKID PLATE SCREW SCREW SKID PLATE
Lep SM4603001-0EN
Issued 09-07
Copyright © 3001-6
Fuel tank
2 19 1
14 13
16 15
18 17 3
1 2 3 13 14
FUEL RESERVOIR PLUG VALVE PLASTIC PROTECTION FUEL PROBE
Lep SM4603001-0EN
15 16 17 18 19
SCREW SEAL SCREW SHIM FILTER
Issued 09-07
4001
Copyright ©
Section 4001 ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING
CNH
Lep SC4604001-0EN
Copyright © 2007 CNH France S.A. Printed in France March 2007
Copyright © 4001-2
TABLE OF CONTENTS ELECTRIC CIRCUITS OPERATION EXPLANATION ................................................................................................... 4 System Chart of Function .......................................................................................................................................... 4 ENGINE CONTROL ....................................................................................................................................................... 7 Fuel Injection Control (Common rail type) ................................................................................................................. 7 GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)........................................................................ 12 RELAYS AND MAIN FUSES (battery compartment) ................................................................................................... 13 FUSE BOX ................................................................................................................................................................... 14 WORK MODE SELECTION ......................................................................................................................................... 15 THROTTLE CONTROL................................................................................................................................................ 22 IDLING CONTROL (AUTO/ONE-TOUCH)................................................................................................................... 25 BREAKER MODE ........................................................................................................................................................ 27 AUTO PREHEAD (GLOW CONTROL) ........................................................................................................................ 28 AUTO WARM UP ......................................................................................................................................................... 31 OVERHEAT PROTECTION ......................................................................................................................................... 32 ATMOSPHERIC PRESSURE COMPENSATION ........................................................................................................ 33 CONTROL WHEN STARTING ENGINE...................................................................................................................... 34 CONTROL WHEN STOPPING ENGINE ..................................................................................................................... 35 EMERGENCY STOP OF THE ENGINE ...................................................................................................................... 35 ENGINE PROTECTION FUNCTION (EPF) ................................................................................................................. 36 FUNCTION LOCKING.................................................................................................................................................. 38 POWER BOOST .......................................................................................................................................................... 39 SWING BRAKE ............................................................................................................................................................ 40 TRAVEL MODE............................................................................................................................................................ 42 TRAVEL ALARM .......................................................................................................................................................... 43 POWER SHUT-OFF DELAY........................................................................................................................................ 44 CONTROL OF HYDRAULIC DRIVEN FAN ................................................................................................................. 45 FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION............................................................................. 54 POWER TRANSISTOR PROTECTION ....................................................................................................................... 56 MONITOR DISPLAY .................................................................................................................................................... 57 Normal Display ......................................................................................................................................................... 57 Message Display ...................................................................................................................................................... 60
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-3 ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ................................................................. 61 Access to monitor displays .......................................................................................................................................61 Machine condition .....................................................................................................................................................62 Diagnostic code ........................................................................................................................................................65 Machine history .........................................................................................................................................................70 Resetting ...................................................................................................................................................................73 MACHINE INFORMATION ........................................................................................................................................... 77 Setting of machine model .........................................................................................................................................77 Changing the language code ....................................................................................................................................79 Display of engine information ...................................................................................................................................79 Re-setting of engine information ...............................................................................................................................79 Selection of injector ..................................................................................................................................................80 TROUBLESHOOTING .................................................................................................................................................. 83 Prior inspections .......................................................................................................................................................83 Reading the organisation charts ...............................................................................................................................84 Procedures ...............................................................................................................................................................85 Fuel ...........................................................................................................................................................................86 Add coolant solution .................................................................................................................................................87 Low engine oil pressure ............................................................................................................................................88 Overheating ..............................................................................................................................................................89 Defective battery charge circuit ................................................................................................................................92 Electrical system troubleshooting .............................................................................................................................94 ELECTRICAL INSPECTION OF COMPONENTS ........................................................................................................ 96 Main pump proportional solenoid ............................................................................................................................100 6 solenoid valve bank .............................................................................................................................................100 Hydraulic oil temperature sensor ............................................................................................................................101 Pressure sensor ......................................................................................................................................................101
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-4
ELECTRIC CIRCUITS OPERATION EXPLANATION System Chart of Function ITEM
FUNCTION
1
Engine control
2
Work mode selection a) H/S/L mode
METHOD Electronic control (common-rail)
Maximum engine speed, pump current, and pressurizing solenoid valve are conMachine setting can be selected accordtrolled according to the selected work ing to conditions such as of workload or mode. fuel efficiency preference, and lifting operation. b) Auto-mode
Selection of auto-mode allows the load to be calculated with pressure of negative Suitable work mode is automatically control P1 and P2 which in turn work selected. mode is switched. c) Load prefectch control Pump current is kept at 0 mA while machine is not being operated.
Pump current and engine controller are controlled by signal from pressure switch.
3
Throttle control
Engine can be controlled continuously Engine speed is adjusted by control of from idling to high idling speed by opera- throttle valve. tor's instruction.
4
Idling control
Engine speed can be switched to/form Pushing knob of switch on the right allows idling by control of onetouch switch. the engine to run idle and pushing it again to return it as it was. It makes engine to run idle while machine Selection of auto-idle allows the engine to is not being operated. run at idling speed automatically in 5 minutes after he lever is shifted to its neutral. Shifting lever makes the engine to return to its normal speed automatically.
5
Breaker mode
Pressing the breaker pedal allows the Turning ON the pressure switch in breaker engine to run at the set speed automati- pilot line allows the engine to run at prevically and boosting pressure will be cut. ously set speed. Also, pump current will be set as that in S-mode and boosting pressure is to be cut.
6
Auto preheat
It helps the engine to start easily at a low temperature. Also, it stabilizes engine speed immediately after start of the engine to reduce exhausting smoke.
7
Auto warm-up
When coolant temperature is low, it allows In case where no operation of the the engine to start warming up automati- machine after the engine has been started cally after it has been started. is carried out when coolant temperature is low, it automatically increases engine speed gradually to warm it up.
8
Overheat protection
When engine coolant temperature has When coolant temperature goes over been increased, reduce injection quantity 100°C, reduce fuel injection quantity. to protect engine. Coolant temperature sensor to ECM.
Lep SC4604001-0EN
Depending on cooling water temperature at the time when the key switch is turned ON, the glow plug is energized for a period of time being set. It is to be energized for a certain period of set time after the engine has been started to reduce exhausting smoke.
Issued 03-07
Copyright © 4001-5 ITEM 9
FUNCTION
METHOD
Correction of atmos- It prevents black smoke and engine dam- Fuel is to be restricted by an atmospheric pheric pressure age when intake air quantity is decreased sensor when altitude is over 2500 meters. such as operating in highland.
10 Control on engine It increases fuel injection according to It monitors coolant temperature when it is start coolant temperature to improve starting under 0°C. It watches a lapse of time after performance.It improves starting perform- cranking has been started. ance when sufficient fuel fails to be injected due to wear in the machine as it has been operated for a long time. 11 Engine stop control
12 Emergency stop 13 Engine function
Engine controller (ECM) recognizes It stops fuel injection from injector.It engine key OFF by turning key switch insructs pressure control valve to opened OFF fully. It makes EGR valve to be fully open.
engine Emergency stop switch is set up with no Signal of emergency stop switch is transengine stop by key switch in mind. ferred to engine controller (ECM) to perform engine stop control.
protection When the engine is operated with water Water temperature, boost temperature, temperature, boost temperature, and and engine oil pressure are supervised, engine oil pressure exceeded the level and engine is protected respectively specified, it is to protect by limitation of the engine output or by stopping the engine
14 Lever lock
It allows the machine not to be operated by control of levers while cab is being moved Up/Down or when the machine will not be needed for operation.
15 Auto boost control
Boost control
When the lever is raised by control of the gate lever on the left console, the lever lock solenoid turns OFF which in turn pilot pressure is cut off.
Whether boost of pressure is needed or not is judged by the input data on load facIt increases main relief pressure by tor of the engine and on pump discharge approx. 10%. pressure. (Boosting for 8 seconds.) Boost -cut control It does not allow boosting according to a certain condition to protect machine and equipment.
Boosting will not function when reserve pressure switches are turned OFF.
16 Swing lock
It disables swing even when the swing Turning ON the swing lock switch allows lever is mistakenly controlled. the swing brake solenoid to be energized to actuate mechanical brake.
17 Swing brake control
When swing lock is OFF, in order to protect swing device, it controls swing mechanical brake ON/OFF automatically according to operating conditions.
It controls swing brake solenoid valve by the data obtained from switches of swing, attachments, and travel pressure, and also from pump discharge pressure.
18 Travel speed switch- It allows travel speed to switch to either It controls solenoid valve by the travel ing-over one of 2 levels. mode switch to switch over tilt angle of swash plate in the traction motor. 19 Travel alarm
Alarm buzzer functions when traveling.
Travel pressure buzzer.
switch
controls
the
20 Power shut-off delay This ensures power supply for engine stop It allows a time-lag until main relay shuts function. off after key switch has been turned OFF. 21 Hydraulic driven fan It performs proper cooling control while control monitoring coolant temperature by driving cooling fan hydraulically. With cleaning mode. Low noise and low fuel consumption.
It controls fan motor speed by current output obtained by entering coolant temperature. Attached reversing function allows radiator fan to be cleaned.
22 Fuel supply pump It makes an automatic stop when fuel tank Enter signal of fuel sensor to turn OFF control becomes full on refueling. switch. Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-6 ITEM
FUNCTION
METHOD
23 Power transistor pro- It protects controller in case where a cir- Over-current detection shuts off transistor tection cuit connected to transistor output is short- output. circuited. 24 Travel speed switch- a) Normal display ing-over It displays current status of the machine. b) Message display Warning. Functioning operation. When to service the machine
Lep SC4604001-0EN
Temperature of hydraulic oil and of coolant temperature, and fuel level are displayed in bar graphs on LCD monitor and work/ travel mode is also displayed. Each information is to be displayed by letters on LCD monitor.
Issued 03-07
Copyright © 4001-7
ENGINE CONTROL Fuel Injection Control (Common rail type) 1. Process to determine quantity of fuel injection 1) System diagram Engine control module (ECM)
CAN communication Basic fuel injection amount
Shovel Controller
Boost pressure sensor input CKP sensor input CMP or G sensor input
Correction Engine coolant temperature correction Barometric Pressure Fuel temperature boost pressure correction Correction between cylinders Q-key correction QR correction
ECT Sensor input
Correction
SCV or PCV opening time determination
Injector coil energizing time Timing determination
Common rail pressure sensor
Common rail Injector coil SCV or PCV Injector Supply pump
Fuel tank
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-8 2) Operation Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load. Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of fuel injection quantity and injection timing for each cylinder. 1) Injection quantity control Based mainly on engine speed and load given to actual machine, Injection rate control is carried out for optimum injection by controlling fuel injector. 2) Injection pressure control Injection pressure is controlled by control of fuel pressure in the common-rail. The right pressure in the common-rail is calculated by using engine speed and fuel injection quantity. The supply pump and the pressure control valve are controlled according to the calculated pressure so that it can discharge proper quantity of fuel to pressure-feed into the common-rail for control. 3) Injection timing control The control substitutes timer function and an appropriate fuel injection timing is calculated by mainly using engine speed and fuel injection quantity to control the injector. 4) Injection rate control In order to improve fuel consumption in the cylinder, a small amount of fuel is injected (pre injection) for ignition at first, then 2nd time injection (main injection) into the ignited cylinder is carried out. In this control, the injection quantity control in section 1) and the injection timing control in section 3) are carried out by controlling injector.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-9
2. Mounting position of accessories related to engine B3 B50
B51 B47 B1
B49
M9
B6
B48 Engine harness connector
S62
R5
A2
EST connector Tech 2 connector ECM memory clear
700.1.04.01.28F
A2 B1 B3 B6 B47 B48 B49
Engine controller Coolant temperature sensor Fuel temperature sensor Air intake temperature sensor Boost pressure sensor Atmospheric pressure sensor Crankshaft position sensor (or engine speed sensor (flywheel mounted))
Lep SC4604001-0EN
B50 Camshaft position sensor (or G sensor: cylinder recognition sensor (detects rotation of cam shaft)) B51 Boost temperature sensor M9 Air conditioner condenser fan motor R5 Fuel sensor S62 Air cleaner sensor
Issued 03-07
Copyright © 4001-10
3. Appearances of accessories related to the Tier 3 emission control regulation A2. Engine controller (ECM)
700-1-04-01-23AF
Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle). Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation. Reliability is equivalent to the unit for current engine meeting Tier 2 emission control regulation (evaluation of single unit has been completed). In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are recorded.
B1. Coolant temperature sensor
B3. Fuel temperature sensor
700.1.04.01.23AI
700.1.04.01.23AG
1 Power, positive (+) 2 Power, negative (-) 3 For water temperature indicator (not in use)
B6. Intake air temperature sensor
700.1.04.01.23AH
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-11
B47. Boost pressure sensor
B50. Camshaft position sensor (or G sensor)
700.1.04.01.23AM
B51. Boost temperature sensor
700.1.04.01.23AK
B48. Atmospheric pressure sensor
700.1.04.01.23AH
R5. Fuel level sensor
700.1.04.01.23AJ
1 Power, positive (+) 2 Power, negative (-) 3 Output
B49. Crankshaft position sensor 700.1.04.01.23AO
S62. Vacuum sensor Operating negative pressure: 6.27 ± 0.29kPa.
700.1.04.01.23AL
Lep SC4604001-0EN
700.1.04.01.23AN
Issued 03-07
Copyright © 4001-12
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)
M3 A4
S54
S15
S16
S51 P1
S63 S14 S17
R3
S53
S1
S64
P6
S13
E4
E52
E51
F21
X8
A1 A2
B61
K5
K6 K32 K11 K10 K3
K2 K33
U1 CS01M598A
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-13 A1 A2 A4 B61 E4 E51 E52 F21 K2 K3 K5 K6 K10 K11 K32 K33
Computer Engine controller Wiper controller Sunload sensor Cab light Cigarette lighter Air conditioner Fuse box Relay-glow plug Relay-horn Relay-rotary light Relay-air conditioner condenser fan Relay-working light (upperstructure/attachment) Relay-working light (cab) Relay, hydraulic fan Main relay
M3 P1 P6 R3 S1 S13 S14 S15 S16 S17 S51 S53 S54 S64 U1 X8
Wiper motor Instrument panel Air conditioner control panel Throttle volume Key switch Overload switch Breaker/crusher switch Horn switch One touch idle Boom raising priority switch Hydraulic function cancellation lever switch Door limit switch Front window limit switch Cooling hydraulic motor switch DC-DC (24 V-12 V) converter Radio connector
RELAYS AND MAIN FUSES (BATTERY COMPARTMENT) F23
F24
F25
F22
1
K7 K8
700.1.04.07.20A2
1 Battery cable F22 Fuse 20 A; main fuse for F11 and F12 circuits F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits F24 Fuse 20 A; main fuse for F2 circuit F25 Fuse 20 A; main fuse for F1 circuit K7 Relay battery K8 Relay safety
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-14
FUSE BOX
CM00E005
F1
Fuse 20 A:
Engine controller
F2
Fuse 5 A:
Computer control, instrument panel and diagnostic test socket
F3
Fuse 20 A:
Computer power
F4
Fuse 10 A:
Hydraulic function cancellation lever switch
F5
Fuse 10 A:
Air conditioner condenser fan
F6
Fuse 10 A:
Rotary light
F7
Fuse 30 A:
Fuel filler pump
F8
Fuse 20 A:
Fuel feed pump
F9
Fuse 30 A:
Glow plug
F10 Fuse 20 A:
Lubricator (option) connector
F11 Fuse 10 A:
Back-up
F12 Fuse 20 A:
Key switch
F13 Fuse 20 A:
Heater /air conditioner
F14 Fuse 5 A:
Air conditioner compressor
F15 Fuse 15 A:
Working light (upperstructure/attachment)
F16 Fuse 15 A:
Working light (cab) and option connector
F17 Fuse 10 A:
DC-DC (24V - 12V) converter
F18 Fuse 15 A:
Wiper and washer
F19 Fuse 15 A:
Horn
F20 Fuse 15 A:
Cigarette lighter and cab seat compressor adjustment
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-15
WORK MODE SELECTION 1) Circuit configuration
Y7 1
S3 S4 P4
3 2
A1
A2
P1 700-1-04-01-23AP
1 2 3 A1 A2
Engine SERIAL communication CAN communication Computer Engine controller
P1 Instrument panel P4 Monitor display S3 Work mode switch S4 Auto mode switch Y7 Main pump proportional solenoid
2) Timing diagram
S3 S4
700-1-04-01-23 AQ
S3 Work mode switch S4 Auto mode switch
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-16 3) Mode selection switch
4) Operation
1. If the machine was in H/S/L mode and was turned off by the key switch, it will restart in S-Mode when it is turned on through the key switch again. (The previous data is reset.)
1. Pushing the mode switch on the monitor display will send a signal to the controller. The controller then switches modes according to the signal it received.
2. By pressing the work mode switch (S3), the modes alternate as follows: S→H→L→S→H. 3. No matter what mode is selected (S4) to start with, pushing the auto-mode switch (S4) once will switch the mode to «auto». Pushing the switch again will switch the auto-mode to S-mode, regardless of the mode that was selected prior to auto-mode. 4. During the auto-mode operation, the work mode switch stays deactivated. The switch will not work to change modes. 5. After the machine has been turned off with auto-mode selected, it will restart in the auto-mode even when the key switch is turned on. (Previous data is retained.)
2. The controller signals the currently selected mode to the monitor via serial communication. The LCD screen switches according to the data sent. 3. The controller transmits the current mode to the engine controller via CAN communication. The engine controller regulates the engine governor according to the data. 4. Also, the engine controller transmits via CAN communication the data on current mode and the actual engine speed. 5. The controller determines the pump current based on the following data: current mode, actual engine speed, target engine speed. The controller then transmits the result to the pump. 6. The LCD on the monitor switches, reflecting the transmission received from controller via serial communication.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-17 5) Switches and LCD
P4
S2
H1
S3
S5
S4
S22
S7
S10
S9
S8
S11
P5
S12
CD00E007A
H1 P4 P5 S2 S3 S4 S5 S7 S8 S9 S10 S11 S12 S22 S22
Audible warning device Monitor display Hourmeter Travel mode switch Work mode switch Auto mode switch Cushion control switch Audible alarm cut out switch Swing brake switch Emergency engine stop switch Working light switch Wiper switch Washer switch Rotary light switch (Europe only) Free swing switch (North America only)
Lep SC4604001-0EN
1
4
2
5
3
P4
6 CS00F521
1 2 3 4 5 6
Travel speed indicator Work mode indicator Idle mode indicator Coolant temperature indicator Hydraulic oil temperature indicator Fuel level indicator
Issued 03-07
Copyright © 4001-18
A) Auto Modes 1) Alteration The current value of «I min» in mode H is changed to that value equivalent in mode L. The engine speed sensing control is carried out even in mode S and «I maxi» is set to the current value equivalent in mode S and «I min» to that equivalent in mode L. The engine speed sensing control is carried out even in auto mode and control it within the range from «I maxi» to «I min» (equivalent in mode L) for both Sa and La. 2) Purpose It lowers pump output automatically to cope with drop of engine power due to use of poor quality fuel and operation in highland. It applies optimum load with fuel cost and cycle time in mind when operated in automatic mode. 3) Circuit configuration
Y7
P1
A1
A2
1 700-1-04-01-23AP
1 Engine A1 Computer A2 Engine controller P1 Instrument panel Y7 Main pump proportional solenoid
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-19 Max.torque point = X engine speed H mode A
Torque
B
L mode
C
900
0
0.5
4.5
Engine horsepower
Target speed (min-1)
S mode A mode
H mode S mode
Horsepower
L mode
5.0
Trottle volume (V)
HImax ((1) mA)
900
C
B
A
Quantity of flow (Q)
Engine speed (min-1) SImax ((2) mA)
H mode
S mode
Imin=L mode ((3) mA)
Pressure (P) P-Q chart of pump 700.1.04.01.23AT2
Mode H: When engine speed is between A rotation and X rotation at maximum torque point, it controls current value range from HI maxi ((1) mA) to I min ((3) mA). Mode S: When engine speed is between B rotation and X rotation at maximum torque point, it controls current value range from SI maxi ((2) mA) to I min ((3) mA) Mode L: When engine speed is C rotation, current value is of mode L ((3) mA). Auto mode: Sa: When engine speed is between B rotation and X rotation at maximum torque point, it controls current value range from ((1) mA) to l min ((3) mA). La: When engine speed is between C rotation and X rotation at maximum torque point, it controls current value range from HI maxi ((1) mA) to I min ((3) mA).
Lep SC4604001-0EN
4) Operation in mode H, S, and L 1. When the target speed of the engine is lower than the speed at maximum torque, the pump current comes to the current value in mode L even if it is operated in mode H or S. (To prevent engine stop). 2. When operating travel alone even it is operated in mode L, the current value in mode S is to be taken (to prevent endless travelling). 3. When using a backup line (breaker, crusher etc.), the current value in mode S is to be taken. 4. Even if it applies to the section 2) or 3) above, the current value in mode L is to be taken in the case of section 1). (To prevent engine stop.) 5. .When in auto idling, put the idling engine speed at 1200 min-1. (For measures against black smoke generated when restoring engine speed by manual control of lever).
Issued 03-07
Copyright © 4001-20 6. When temperature of engine cooling water is too low or when power-supply voltage applied to the engine controller is too low, increase the idling speed to prevent over-cooling and/or running out of battery. 5. Operation in auto mode 1. When auto mode has been selected, start the machine with mode La first then select mode «Sa» according to working conditions. 2. In addition, the mode can be changed automatically from Sa to La. 3. When water temperature is less than 50°C (122°F) and oil temperature is less than 25°C (77°F), control in auto mode will not be carried out even if the auto mode has been selected and the mode is fixed to La selected on starting.
4. Once water temperature reaches more than 50°C (122°F) and oil temperature more than 25°C (77°F) however, control in auto mode starts and continues operating in this mode if water and/or oil temperature is dropped again. 5. If travel pressure switch is turned ON during control in auto mode, work mode will not be changed over while it is being turned ON. 6. (If travel pressure switch is turned ON during control in mode Sa, mode Sa is to be held, and similarly if the switch is turned ON during control in mode La, this mode is to be held).
Set value in each mode Mode
Designation
Unit (MAX) (When travelling)
H Pump current
Engine speed
2000
-1
-
min
Engine speed
Set value
-1
min
(I MAX)
mA
490
(I MIN)
mA
240
(When in no control)
mA
< 50
-1
min
1800
(I MAX)
mA
405
(I MIN)
mA
240
(When in no control)
mA
< 50
(MAX)
min-1
1700
(STD)
mA
< 50
(When in no control)
mA
< 50
(MAX)
min-1
1800
(I MAX)
mA
490
(I MIN)
mA
240
(MAX)
min-1
1700
(I MAX)
mA
490
(I MIN)
mA
240
(When in no control)
mA
< 50
min-1
900
(MAX)
S Pump current
Engine speed L Pump current Engine speed Mode Sa Pump current Engine speed Mode La Pump current
Engine speed in idling Engine speed in auto idling Engine speed at maximum torque
Lep SC4604001-0EN
min
-1
1200
-1
1500
min
Issued 03-07
Copyright © 4001-21
B) Load pre-fetch control 1) Purpose Pump current is controlled as measures against black smoke. 2) Circuit configuration
Y7 B26 1 A2
B27 A1 700.1.04.01.23AU
1 Engine A1 Computer/Controller A2 Engine controller
B26 Upper pilot pressure switch (yellow band) B27 Travel pilot pressure switch Y7 Main pump proportional solenoid
3) Operation 1. .When no operation is carried out (attachment and travel pressure switches OFF), the pump current is always 0 mA regardless of operation mode and engine speed. 2. .When attachment or travel pressure switch is turned ON, the controller provides pump current so that it can get to the set current for the work mode being selected after 0.8 second. * No control for decreasing transient load has been employed for machines above current model of CX330. Control for decreasing transient load is illustrated below: Since engine response (or returning property) has been improved (or no difference between target speed and actual speed), if an abrupt engagement of the lever from inching operation is carried out, and when difference between target speed and actual speed reaches within 150 min-1, pump current of 0 mA is to be applied to ease the engine load. This is for the purpose of taking measures against black smoke and of prevention from engine stop.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-22
THROTTLE CONTROL The analog voltage signal from throttle potentiometer is provided to the controller in the machine to transfer it to the engine controller (ECU) via CAN communication circuit together with work mode. 1) Purpose Engine speed can be set by no dependence of the engine controllers on ISUZU side. 2) Circuit configuration TARGET SPEED
ENGINE SPEED
5V SIG
THROTTLE VOLUME
GND
A1
CAN-H
1
A2
CAN-L
ENGINE CONTROLLER
ENGINE CONTROLLER
H mode
5.0
S mode
Input voltage (V)
A
L mode
B C
A mode 900
0
100
Throttle Volume Position (%)
0
0.5
4.5
5.0
Input voltage (V) 700.1.04.01.23AV
1 Engine A1 Computer/Controller
A2 Engine controller
3) Operation 1. The controller determines the target speed from the position of throttle potentiometer and the work mode currently being entered to transfer the data to the engine controller (ECM) via CAN communication circuit. 2. ECM determines fuel injection quantity from the calculated target speed and the data obtained from each sensor (such as actual engine speed, fuel temperature, and boost temperature) to transfer it to the supply pump and to the injector for engine control.
4. When CAN communication linking between the controller and the engine controller (ECM) is stopped, the engine speed is fixed to a certain specified speed and the throttle potentiometer specifying engine speed will not be functioning. (Specified speed: 1050min-1). The specified speed, for the purpose of emergency escape, has been set as the engine speed which will not damage the breaker while the engine is running.
3. When the engine is rotated at a speed less than that at the maximum torque by controlling throttle potentiometer, the pump current becomes that of mode L even if work mode is selected either to mode S or to mode H.
Lep SC4604001-0EN
Issued 03-07
1 2 3
CONTROLLER
CN.50
ENGINE STOP
CN.52
G1 G2 ACC M ST
1.25RW 4 2 5 3 6 1 21
11 4 5
43 29 39
ENGINE STOP
CAN H CAN L
5V THROTTLE SIG THROTTLE VOLUME A GND
24VB
HEAT OFF ACC ON ST
B
1.25LgR 0.85GrR 0.85LY 0.85LG 0.85BL
3 4 6 7 8
1.25LgR 0.85GrR 0.85LY 0.85L 0.85BL
CN.A0
ENGINE STOP
MONITOR SWITCH
0.85P 0.85PL
BrR
0.85LY 0.85LG 0.85BL
WR
1.25RW
1
1.25RW
2 3 5
1.25LgR WR 0.85GrR
1.25LgR WR 0.85GrR
1.25GR
5
1.25GR
WR 0.85LgR GrR BrR YR 0.85P 0.85PL
3LR
3
2LR
16 WR 17 0.85LgR 18 GrR 19 BrR 20 YR 21 P 22 PL
MAIN RELAY
WR
1.25LgR
BATTERY RELAY
0.85Y 0.85YL 0.85BY
1 3 2
0.85BO 0.75OL
SAFETY RELAY
t ˚C
AIR INTAKE TEMP. SENSOR
CN.A1
BARO SENSOR
1 2
3
GLOW RELAY
0.85GrR
B48
ENGINE CONTROLLER (ECM)
1.25B 1.25B 1.25B 0.85BG 0.85BG 0.85BG 1.25GR 1.25GR BrR
CN.19
THROTTLE VOLUME
1.25LgR 0.85GrR
YR 0.85LgR YR BL
0.85LY 0.85L 0.85BL
P PL
18 37
1 3 4 43 62 81 2 5 10
CN.6 CN.1
21 24 40 41
0.85LgR LgR GrR 0.75Y 0.75WR 0.75W 0.75RG
CN.3 GrR WR 0.85BY 0.85Y BL BL 0.75L 0.85YL 0.75OL
WR
KEY SWITCH
74 0.75WL 79 0.75BY 80 0.75YR
CN.22 CN.21
A1 CN.23
S9
46 47 60 61 63 64 67 71 72
K33
83 84 89 95
CN.A8
0.75W 0.75GR 0.75YG 0.75G 0.75WG 0.75R 0.75W 0.75W 0.75G 0.75L
CN.A7
103 0.75GB
CN.T3
97 91 92 93 94 87 82 90 101 98
B6
100 0.85BL
5 1 2 3 4 2LR YR BG 1.25GR
Lep SC4604001-0EN
K2
3LR
0.75WB 0.75GB 0.75YB 0.75WG 0.75G 0.75YG 0.75GR
0.75R 0.75W 0.75G 0.75G 0.75L BW 0.75L BL 0.75WR 0.75WL 0.75RG 0.75GR 0.75BR 0.75RY 0.75YB 0.75BY
0.75GR
0.75Y 0.75P 0.75W
1 2
1 2 3 4 5 6
12 13 14 1 2 3 5 6 7 15 8 16 17 9 10 11
8 7 6 4 3 2 1
0.75GW 5 0.75WL 6 0.75GB 7 8 0.75G 0.75WB 9 0.75WR 10
1.25RG 1.25RW
CN.A5
0.75P 0.75G 0.75L 0.85BW 0.75BR 0.75YB 0.75WB
R3 CN.A2
105 106 107 108 109 110 111
S1 K8
5 1 2 3 4
1 CN.A4
2WR LgR BrR 2LR
K7 CN.A6
0.75P 0.75WB 0.75WR 1.25RW 0.75G 0.75WL 0.75GW 0.75GB 1.25RG
GLOW PLUG
M
No.4 CYLINDER
No.2 CYLINDER
No.3 CYLINDER
No.5 CYLINDER
No.6 CYLINDER
No.1 CYLINDER
PCV2
PCV1
FUEL LEAKAGE TEMP. SENSOR t ˚C
OIL PRESS. SENSOR
BOOST PRESS. SENSOR
BOOST TEMP. SENSOR t ˚C
WATER TEMP. SENSOR t ˚C
G(MRE) SENSOR
+
CRANK ANGLE (MPU) SENSOR
COMMONRAIL PRESS. SENSOR
U V W
EGR POSITION SENSOR
U V W
EGR MOTOR
M15
113 114 115 116 117 118 119 120 121
ENGINE
Copyright © 4001-23
4) Throttle Control Relation Electric Circuit Diagram
B53 B52 B49 B50 B1 B51 B47 B21 B3 Y33 Y34
R1
CN.A3
A2
700-1-04-01-23 aw
Issued 03-07
Copyright © 4001-24 1 Engine A1 Computer A2 Engine controller B1 Coolant temperature sensor B3 Fuel temperature sensor B6 Air intake temperature sensor B21 Engine oil pressure switch B47 Boost pressure sensor B48 Ambient air (barometric) pressure sensor B49 Crankshaft position sensor B50 Camshaft position sensor B51 Boost temperature sensor B52 Common rail pressure sensor B53 Exhaust gas recirculation valve position sensor K2 Relay-glow plug K7 Relay battery K8 Relay safety K33 Main relay M15 Exhaust gas recirculation motor R1 Glow plug R3 Throttle volume S1 Key switch S9 Engine emergency stop switch Y33 Supply pump valve (pcv1) Y34 Supply pump valve (pcv2)
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-25
IDLING CONTROL (AUTO/ONE-TOUCH) 1) Circuit configuration
P1
B26 H1
B27 S16 B25
P4
A1
A2
B22
1 700.1.04.01.1.23AX
1 Engine A1 Computer/Controller A2 Engine controller B22 Swing pilot pressure switch B25 Breaker pilot pressure switch B26 Upper pilot pressure switch (yellow band)
B27 Travel pilot pressure switch H1 Audible warning device P1 Instrument panel P4 Monitor display S16 One touch idle
2) Switching between auto idle and one-touch idle
8. LCD displays “IDLING” on the monitor during idling control.
1. Pushing the knob switch (IN1) down and holding it for 3 seconds will trigger the modes to toggle between auto and one-touch. When the mode switches, the ON/OFF display on the auto idle section of the LCD also switches, and the buzzer buzzes for 3 seconds.
3) Switching between auto idle and one- touch
2. At the time of auto idle/one-touch idle selection, the previous setting will still prevail even after the key switch was turned ON. (Previous data is retained.) 3. The LCD will display ON/OFF status of auto idle. ON on the display indicates the auto idle, OFF indicates one-touch idle. 4. If there occurs no handling through the lever for 5 seconds with auto idle turned ON (both attachment pressure switch and travel pressure switches are OFF), the engine speed automatically goes back to the idling state. (For 5 seconds, the initial setting prevails. Programming is possible through adjusting settings on the back panel for the duration between 1 and 30 seconds.) 5. During auto idle, if operated via lever while engine is idling (either attachment pressure switch or travel pressure switch is on), the engine speed automatically goes back to the previous rate. 6. Even during auto idle, idling/recovery operation is attained by pressing the knob switch (one-touch switch).
idle 1. When setting idling revolutions based on conditions described in 2). Switching between auto idle and one-touch idle, the controller transmits an idling signal to the engine controller via CAN communication. Also, a signal is sent to the monitor display via serial communication to display “IDLING” on the screen. 2. The engine controller, upon receiving the signal, selects idling mode and adjusts engine speed to that of the idling state. 3. The monitor displays “IDLING” on the LCD according to the signal sent. 4. When recovering from idle control based on the conditions described in 2). Circuit configuration, the controller transmits a signal to the engine controller via CAN communication conveying the previous engine mode selection. Also, the serial transmission that has been sent to the monitor for displaying “IDLING” on the screen will be terminated. 5. The engine controller, depending on the mode signal received, switches the idling mode back to the previous mode and adjusts the engine speed. 6. The monitor recognizes the termination of the idling signal transmission and stops the “IDLING” display on LCD.
7. When auto idle is OFF (i.e. during one-touch idle), idling/recovery is attained by simply operating the knob switch (one-touch idle switch), whether or not the machine was manoeuvred though the lever. Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-26 4) Timing diagram 1) Timing diagram for auto idle ON/OFF selection
POWER 24V 0V IN1 OFF (5V) (KNOB SW) ON (0V) AUTO IDLE
700-1-04-01-23 AY2
2) Timing diagram when auto idle is ON
IN1 OFF (5V) (KNOB SW) ON (0V)
IN3 OFF (5V) PRESSURE SW (TRAVEL) ON (0V) ENGINE SPEED IDLE 3) Timing diagram when auto idle is OFF
700-1-04-01-23 AZ2
IN1 OFF (5V) (KNOB SW) ON (0V) IN2 OR IN3 OFF (5V) ON (0V) ENGINE SPEED IDLE
700-1-04-01-23 BA2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-27
BREAKER MODE 1. Alteration Optimization of pump current in mode S and in mode L at the engine speed with the breaker being used. Pump current at engine speed of between 1200 and 1500min-1 is applied from that in mode L to that in mode S.
2. Purpose Although in the breaker mode up to now, pump current in mode S is to be applied at engine speed of more than 1500 min-1, It spreads the speed range in mode S so that the machine can be operated in less than that of the flow-rate.
3) Circuit configuration
R3 Y7 1
S14
B25
A2 A1 700.1.04.01.23BB
1 A1 A2 B25
Engine Computer/Controller Engine controller Breaker pilot pressure switch
R3 Throttle volume S14 Breaker/crusher switch Y7 Main pump proportional solenoid
4) Operation 1. When the breaker mode switch is turned ON by locker switch on the console (left side) and the pressure switch in backup line is turned ON, it controls to rotation of the breaker. 2. When the engine is rotated at a speed less than that set for the breaker by controlling the throttle potentiometer, engine speed will not be increased to the speed set for the breaker even if the breaker is operated. 3. If the pressure switch in backup line is turned ON regardless of breaker mode switch input, the pump current is to be at the current value in mode S irrespective of operation of at that time. (However, when the engine speed is less than 1200min-1, pump current becomes that in mode L).
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-28
AUTO PREHEAD (GLOW CONTROL) ture, at the same time when the key switch is turned ON.
1) Alteration Only the circuit structure and the pre-glow control are different. (Refer to time chart attached) It is the same that the pre-glow starts, according to water tempera2) Circuit configuration
ENGINE CONTROLLER
KEY SWITCH S1
B
M
ST
CONTROLLER
A2
OFF
ENGINE
GLOW PLUG
ON ST
TO BATTERY RELAY TO STARTER RELAY
K2 GLOW RELAY
A1 ENGINE START KEY ON CAN-H GLOW RELAY CAN-L
1
700.1.04.01.23BC
1 Engine A1 Computer/Controller A2 Engine controller
K2 Relay-glow plug S1 Key switch
3) Operation 1. When the key switch is turned ON, the engine controller (ECM) calculates pre-glow time from engine cooling water by using the attached map. 2. ECM turns ON the glow relay output during calculated pre-glow time to transfer the glow lamp signal through CAN communication circuit to the controller displaying «ENGPREHEAT» on the monitor. 3. The glow relay output continues regardless of ON/ OFF of the glow lamp signal.
6. Since the control mentioned above starts immediately after the key switch has been turned ON, «ENG PREHEAT» will not be displayed on the monitor unless the pre-glow time passes more than 3 seconds (below -5°C) (23°F). *The glow lamp time map is added from the engines meeting the emission control regulation of 3rd-stage. *Refer to attached sheets for the glow control time according to water temperature and for the time chart.
4. After the engine has been started, it turns ON the glow relay output again only when cranking the engine. The glow lamp signal will not be transferred at this time. 5. When the key switch returns to ON from the «start» (when cranking is completed), it calculates afterglow time by using the attached map. The glow lamp signal will not fee transferred at this time.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-29 4) Water temperature control map
GLOW LAMP TIME (sec)
1) Glow lamp time (it transmits by CAN communication)
°C -4
14
50 68 32 ENGINE COOLANT TEMPERATURE
86
104 °F
700-1-04-01-23 BD2
PRE GLOW TIME (sec)
2) Pre-glow time
-4
14
50 68 32 ENGINE COOLANT TEMPERATURE
86
°C 104 °F
700-1-04-01-23 BE2
AFTER GLOW TIME (sec)
3) After glow time
-4
14
68 50 32 ENGINE COOLANT TEMPERATURE
86
°C 104 °F
700-1-04-01-23 BF2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-30 5) Timing chart 1) When in normal operation START KEY SWITCH
ON OFF
ON
GLOW LAMP
OFF
ON GLOW RELAY
OFF
GLOW LAMP TIME
PRE GLOW TIME
AFTER GLOW TIME 700-1-04-01-23 BG2
2) When the engine has been started after pre-glow is completed START
ON
KEY SWITCH
OFF
GLOW LAMP
OFF
ON
ON OFF GLOW RELAY
GLOW LAMP TIME
PRE GLOW TIME
CRANKING GLOW TIME
AFTER GLOW TIME
700-1-04-01-23 BH
3) When the engine has been started before glow lamp goes off START KEY SWITCH
GLOW LAMP
GLOW RELAY
ON OFF
ON OFF
ON OFF
GLOW LAMP TIME PRE GLOW TIME
CRANKING GLOW TIME
AFTER GLOW TIME 700-1-04-01-23 BI2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-31
AUTO WARM UP 1) Circuit configuration
R3 B26
H1
S16
A2 P4
1
A1 700.1.04.01.23BJA
1 A1 A2 B26
Engine Computer/Controller Engine controller Upper pilot pressure switch (yellow band)
H1 Audible warning device P4 Monitor display R3 Throttle volume S16 One touch idle
2) Operation 1. A coolant temperature sensor is installed inside the engine. The signal from this sensor goes out to the engine controller and is converted into a temperature value. The engine controller then transmits the coolant temperature data to the controller via CAN communication.
5. Once auto warm-up control is cancelled, the controller does not initiate auto warm-up control again unless key switch is turned from OFF to ON. 6. While controller is executing the auto warm-up control, an “AUTO WARM UP” message is displayed on the monitor's LCD.
2. If the coolant temperature is below 50°C (122°F) after engine starts, the controller transmits the auto warm-up signal to the engine controller via CAN communication. 3. The engine controller executes the auto warm-up control upon receiving the signal transmission from the controller. 4. The controller terminates the auto warm-up control on the following conditions. The engine controller terminates the auto warm-up control once the command is cancelled. *When one of the following switches turns on: attachment pressure switch, travel pressure switch, and knob switch (one-touch idle switch). *When throttle volume is changed. *When engine speed stays above 1800 min-1 for 3 minutes.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-32 3) Auto warm-up control AUTO WARM-UP COMPLETE ENGINE SPEED (MIN -1)
ENGINE SPEED (MIN -1)
AUTO WARM-UP COMPLETE
TIME THROTTLE POSITION
TIME THROTTLE POSITION
DURATION OF OPERATION
DURATION OF OPERATION 700-1-04-01-23-BK2
OVERHEAT PROTECTION water temperature exceeds 100°C (212° F). * Waning «OVER HEAT» is to be displayed on the monitor in actual machine when temperature exceeds 105°C (221° F).
1) Purpose It is the function protecting the engine by restriction of fuel injection quantity which in turn reduces engine out put forcibly when water temperature has kept on rising. The control starts functioning at the moment when 2) Water temperature-fuel injection quantity
Q RESTRICTION BY OVERHEAT PROTECTION
Q RESTRICTION RATE (%)
120
100
80
60
40
20
0
32
95
100
105
110
115
120
125
203
212
221
230
239
248
257
°C 266 °F
130
ENGINE COOLANT TEMPERATURE 700.1.04.01.23BL2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-33
ATMOSPHERIC PRESSURE COMPENSATION prevent the engine from being damaged (prevention of over-revolution of turbo) due to temperature rise of exhaust gas.
1) Purpose Purpose is to prevent black smoke from increasing because an excessive fuel is fed in the combustion chamber of the engine due to lack of intake air and to 2) Map
ALTITUDE _ TORQUE OUTPUT DROP DUE TO CHANGE IN ENVIRONMENT
(lbf-ft) (N-
OUTPUT DROP DUE TO FUEL COMPENSATION
1032
TORQUE
959 885 811 737 664 590
(m) 1640
3285
4921
6562
8202
9842
11483
13123
14764
16404 (ft)
ALTITUDE 450.1.04.01.28AO
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-34
CONTROL WHEN STARTING ENGINE 1) Starting control (by monitoring water temperature 1. Purpose When water temperature is below 0°C (32°F), Purpose is to ensure starting performance of the engine
in cold temperature by making fuel injection according to water temperature.
2) Long cranking control starting Q (fuel injection) will not be injected in such case where an injector is worn out, after the specified time has passed from the time when cranking was started.
1. Purpose While aiming at reduction of black smoke when starting engine, the purpose is to improve starting performance by increasing starting Q (fuel injection) by fixed quantity, as a backup when sufficient 2. Time chart START KEY SWITCH
ENGINE SPEED
ON 1.5 sec
OFF
IDLING CRANKING 0
UP-Q
STARTING Q
ST-Q NL-Q 0
ST-Q: Standard starting Q, UP-Q: Starting Q after increase of quantity, NL-Q: Q in no lord 700.1.04.01.23BN2
3) Starting control when number of effective cylinders is reduced 1. Fuel quantity to be injected by faulty injectors is allotted to other normal injectors (total quantity is to be the same).
1. Purpose Purpose is to correct fuel injection quantity to assure starting performance of the engine with a view to escaping in an emergency when a certain number of stopped injectors are detected by trouble diagnosis.
2. In case where number of faulty cylinders is over half of the total numbers, increase of fuel injection.
2. Operation 3. Number of cylinders-Correction factor Number of effective cylinders Correction factor
Lep SC4604001-0EN
6
5
4
3
2
1
0
1.0
1.2
1.5
2.0
1.0
1.0
1.0
Issued 03-07
Copyright © 4001-35
CONTROL WHEN STOPPING ENGINE 1. Operation 1) Turn OFF the key switch. 2) When the engine controller recognizes that the key is turned OFF, steps 3) through 5) below are carried out simultaneously. 3) Fuel injection quantity stops to be calculated. 4) Pressure control valve (PCV) is instructed so that it is fully closed.
5) EGR valve is instructed so that it is fully closed and its initial point is corrected. 6) After steps 3) through 5) have been completed, information such as history failure is written in EPROM in the ECM. 7) Turn OFF the main relay and turn OFF the power supplied to ECM.
EMERGENCY STOP OF THE ENGINE 1. Alteration In current type 3 (engine meeting emission control regulation of 2nd-stage), depression of the emergency stop switch allows the engine stop motor to rotate to the stop position by way of the relay and allows the engine governor to control for stopping engine by the engine stop signal from the engine controller (ECU). In the next type (engine meeting emission control regulation of 3rd-stage), depression of the emergency stop switch allows the controller to transfer engine stop signal to ECM controlling the engine to be stopped. 2. Circuit configuration
MONITOR DISPLAY 24V-OUTPUT CN6-21(PNP)
P4
ENGINE STOP WR501
1 BrR530 CN3-43
S9
SWITCH (EMERGENCY STOP)
A1
A2
CONTROLLER
ENGINE CONTROLLER
ENGINE
700.1.04.01.23BO
1 Engine A1 Computer/Controller A2 Engine controller
P4 Monitor display S9 Engine emergency stop switch
3. Operation 1) Depression of emergency stop switch on the monitor display allows the output signal from transistor in the controller to be turned ON and at the same time, the engine stop signal is transferred from the controller to the engine controller (ECM) 2) ECM performs stopping control for the engine.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-36
ENGINE PROTECTION FUNCTION (EPF) 1) Purpose When the engine is operated with water temperature, boost temperature, and engine oil pressure exceeded the level respectively specified, it is to protect by limitation of the engine output or by stopping the engine. 2) Operation 1) Water temperature monitoring Setting
Time
100°C
-
105°C
Engine control
Indication in bar graph for ECM: Decrease of fuel injection rate Machine controller: Normal water temperature:
Error codes
Reset
Monitor message
-
-
-
M00F0
Indication in bar graph for water temperature: Below 8th graduation
At 8th graduation 110°C
5 sec.
ECM: Decrease of fuel injection rate Machine controller: Idling
M00F1
120°C
5 sec.
ECM: Decrease of fuel injection rate Machine controller: Engine stop
M00F2
OVER HEAT
Turn ON key after engine has been stopped.
1. Engine protection will not function if error codes, E0117 (water temperature sensor low voltage abnormality) and E0118 (water temperature sensor high voltage abnormality), are indicated. 2. Engine protection will not function if error codes, E2104 (CAN-bus abnormality), E2106 (CAN time-out abnormality), and M0090 (CAN communication error), are indicated. 3. Engine protection by water temperature will start functioning 1 minute after the engine has been started (in order to detect water temperature in steady state). 2) Boost temperature monitoring Setting
Time
80°C
5 sec.
90°C
5 sec.
Error codes
Reset
ECM: Normal Machine controller: Idling
M00F3
When temperature below 70°C continues for 30 sec.
ECM: Normal Machine controller: Engine stop
M00F4
Engine control
Monitor message
OVER HEAT
Turn ON key after engine has been stopped
1. Engine protection will not function if error codes, E1112 (boost temperature sensor low voltage abnormality) and E1113 (boost temperature sensor high voltage abnormality), are indicated. 2. Engine protection will not function if error codes, E2104 (CAN-bus abnormality), E2106 (CAN time-out abnormality), and M0090 (CAN communication error), are indicated. 3. Engine protection by boost temperature will start functioning 1 minute after the engine has been started (in order to detect boost temperature in steady state).
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-37 3) Engine oil pressure monitoring Setting
Time
40KPa
5 sec.
Engine control ECM: Normal Machine controller: Engine stop
Error codes
Reset
Monitor message
M00F5
Turn ON key after engine has been stopped
LOW OIL PRESS
1. Engine protection will not function if error codes, E0522 (engine oil pressure sensor low voltage abnormality) and E0523 (engine oil pressure sensor high voltage abnormality), are indicated. 2. Engine protection will not function if error codes, E2104 (CAN-bus abnormality), E2106 (CAN time-out abnormality), and M0090 (CAN communication error), are indicated. 3. Engine protection will not function if error code of E1633 (5V power supply 3 voltage abnormality) is indicated. 4. Engine protection by engine oil pressure will start functioning 30 seconds after the engine has been started (in order to detect engine oil pressure in steady state). *Introduce failure codes of machine system for setting error codes. *Pump output is always functioning according to “L” mode while idling. *Turning key switch OFF allows function of engine protection to be reset. (Engine runs for 30 sec. even if something is wrong.) *Error codes are to be recorded as well as recording other codes. *The engine is to be stopped by means of emergency engine stop signal from PNP output. *The engine is to be judged as started if it runs at a speed of more than 500 min-1. 4) Select for setting of engine protection function Since engine protection function has been set as standard, the setting can also be cancelled. RESET (RST1)
Selection of engine protection function
Engine protection function (0=ON, 1=OFF)
800-1-04-01-26F
1. Every time the traveling mode switch turns ON, the setting at “AU” is to be shifted as in the order of 0000→0001→0010→0011→0000 repeatedly. 2. Turn ON the operation mode switch for 10 seconds. 3. Buzzer sounds to indicate that the settings have been memorized. 4. Turn the OFF key switch. *If “NO against engine protection function” is chosen, function of engine output limitation/engine stop is cancelled but error codes are displayed and saved as records. NOTE: At "AU" selection, auto boost control and engine protection function can be set at the same time.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-38
FUNCTION LOCKING 1) Circuit configuration
F21 K7 F4 F23 Y2 S51
G1
700.1.04.01.23BP
F4
Fuse 10 A; hydraulic function cancellation lever switch F21 Fuse box F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits
G1 Battery K7 Relay battery S51 Hydraulic function cancellation lever switch Y2 Pilot pressure solenoid valve (blue band)
2) Timing diagram
KEY SWITCH
POWER
GATE BAR
POSITION
RUN STOP
LEVER LOCK
SOLENOID VALVE OPERATION
ENABLE
DISABLE 700-1-04-01-23 BQ2
3) Operation 1) By positioning the gate lever on cab console (left) toward operation (gate lever sticks out when this is done) while the machine is powered on, the limit switch will be turned ON (closed) and the lever lock solenoid valve will be ON. 2) When the lever lock solenoid valve is ON, pressure can reach the pilot line, enabling the machine to operate.
Lep SC4604001-0EN
3) By positioning the gate lever toward entering/leaving cab (gate lever stays housed), the limit switch will be turned OFF (open) and the lever lock solenoid valve turns OFF. 4) When the lever lock solenoid valve turns off, pressure cannot reach the pilot line. Thus the operation of the machine will be disabled.
Issued 03-07
Copyright © 4001-39
POWER BOOST 1) Circuit configuration
A2 B42 A B44 B27 Y5 B25
A1 700.1.04.01.23BR
A A1 A2 B25
B27 B42 B44 Y5
Main relief (standard) Computer Engine controller Breaker pilot pressure switch
Travel pilot pressure switch Pump pressure sensor (P1) Pump pressure sensor (P2) (yellow band) Power-up solenoid valve (yellow band)
2) Increasing the pressure in each work mode Mode Auto
Automatic power boost (*) 31.4 to 34.3 MPa (4554 ↔ 4974 psi)
H mode (Pressure)
Automatic power boost (*) 31.4 to 34.3 MPa (4554 ↔ 4974 psi)
S mode (Pressure)
Automatic power boost (*) 31.4 to 34.3 MPa (4554 ↔ 4974 psi)
L mode (Pressure)
Constant power boost (*) 31.4 to 34.3 MPa (4554 ↔ 4974 psi)
* When the travel pilot pressure switch (B27) or the optional breaker pilot pressure switch (B25) is activated, power boost is deactivated. 3) Operation When operating in H or S mode, the computer (A1) records the ratio between: - The engine load transmitted by the engine controller (A2). - The hydraulic circuit load transmitted by the pump pressure sensors (P1) (B42) and (P2) (B44).
Lep SC4604001-0EN
If the pump pressure (P1) or (P2) is greater than 29.9 MPa (4351 psi) and the load ratio is within a range of ± 5% for 2 seconds, the computer (1) activates the power-up solenoid valve (yellow band) (Y5) for 8 seconds, which increases the main pressure. When the travel pilot pressure switch (B27) or the optional pilot pressure switch (B25) is activated, the computer (A1) deactivates the power-up solenoid valve (yellow band)(Y5).
Issued 03-07
Copyright © 4001-40
SWING BRAKE 1) Circuit configuration
S8
B22 B26 S1
B27 B42
1
B44 Y3
P1 A1
700.1.04.01.23BS
1 Swing brake A1 Computer B22Swing pilot pressure switch B26Upper pilot pressure switch (yellow band) B27Travel pilot pressure switch B42Pump pressure sensor (P1)
B44Pump pressure sensor (P2) (yellow band) P1 Instrument panel S1 Key switch S8 Swing brake switch Y3 Swing brake solenoid valve (pink band)
2) Operation of the swing brake control 1) Overview 1. Pressing the swing lock switch on monitor display will turn on the red LED, activating the swing lock control. Pressing the swing lock switch again will turn off the LED, and the swing lock is deactivated. 2. During swing lock control, controller's transistor output turns on and the mechanical brake that is built in the swing motor turns on. 3. The ON/OFF state of the swing lock holds when turning the key switch from OFF to ON.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-41 2) Timing diagram KEY SWITCH
POWER
SWING LOCK SWITCH OUT (IN1)
SWING PRESSURE SWITCH (IN3)
SWING LOCK
LED
700-1-04-01-23 BT2
3) Swing brake auto control 1) Overview The auto control of the swing brake takes place when the swing lock is OFF. The auto control also releases the mechanical brake automatically during a digging operation as well as during swing operation. If the operation is halted, the auto control turns on the mechanical brake automatically. The detailed conditioning for ON/OFF of the swing mechanical brake is shown below. • The swing brake will be turned OFF based on the following conditions. 1. Pressure switch (swing) is ON 2. P1>15 MPa (2175 psi) or P2>15 MPa (2175 psi) • The swing brake will be turned ON based on the following conditions. 1. Pressure switch (attachment) stays OFF for 5 seconds 2. Key switch is OFF • The swing mechanical brake will be deactivated once when the pump delivery pressure (P1 or P2) grows over 15 MPa (2175 psi) during travel. However, it will take effect in 5 seconds.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-42
TRAVEL MODE 1) Circuit configuration
P1 A1
B42
B44
S2
B43 B27 Y4
P4 700.1.04.01.23BU
P1 P4 S2 Y4
A1 Computer B27Travel pilot pressure switch B42Pump pressure sensor (P1) B43Pressure sensor (nega-cont.) B44 Pump pressure sensor (P2) (yellow band)
Instrument panel Monitor display Travel mode switch 2 stage travel solenoid valve (red band)
2) Timing diagram
Power supply
24 V
Travel mode switch
ON OFF
IN1
5V 0V
Speed
0V
I
II
I
II
I
II
I
I
II
700-1-04-01-23 BV
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-43 3) Operation
Travel speed II selected
When the starter motor switch is positioned in the «ON» position, the 1st speed is selected by default.
1. When the pressure of the pumps P1 or P2 is less than 580 psi, the output from the computer (OUT)(A1) of the 2 stage travel solenoid valve (Y4) is deactivated (1st speed).
Every time the travel mode switch is pressed (S2), the computer (A1) registers a signal (IN1: 0 volts). The computer (A1) changes the travel speed in the following way I-> II, II -> I and transmits the modifications to the monitor display (P4). Travel speed I selected The output from the computer (OUT)(A1) of the 2 stage travel solenoid valve (Y4) is deactivated (1st speed).
2. When the pressure of the pumps P1 or P2 is greater than 580 psi, the output from the computer (OUT)(A1) of the 2 stage travel solenoid valve (Y4) is activated (2nd speed). When the attachment controls are operated, the output from the computer (OUT)(A1) of the 2 stage travel solenoid valve (Y4) cannot be activated or deactivated. 3. When the travel pressure is greater than 3582 psi, the travel motor displacement change spool is pushed back and the swash plate angle is in high displacement (1st speed). 4. Travel speed II may still be selected if necessary, for example for cleaning tracks.
TRAVEL ALARM 1) Circuit configuration Pressure switch (Travel)
B27 Travel alarm
Controller
H2
A1 700.1.04.01.23BW
A1 Computer B27Travel pilot pressure switch
H2 Travel alarm
2) Timing diagram The pressure switch (travel) will be turned ON through the travel lever operation. The travel alarm will sound for 10 seconds, then stop. Power
Travel alarm 700.1.04.01.23BX
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-44
POWER SHUT-OFF DELAY 1) Alteration Power being supplied to the engine controller is shut off via main relay and at the same time, the battery relay stops to be energized shutting off the power to the machine. Delayed operation time is 4 seconds (immediately after 0 min-1 of engine speed) from the key is turned ON to OFF, and approximately 7 seconds after starting to stopping the engine. 2) Circuit configuration BATTERY RELAY KEY SWITCH
S1
KEY SWITCH B
A1
M
ST
- +
OFF
CONTROLLER
- +
K7
ON ST IS-IGKEY IS-START
OS-MAINR OS-MAINR
K33
MAIN RELAY
PS-+B PS-+B
A2
ENGINE CONTROLLER
700.1.04.01.23BY
A1 A2 K7
Computer/Controller Engine controller Relay battery
K33 Main relay S1 Key switch
3) Timing diagram
KEY SWITCH
S1
ENGINE SPEED
ON OFF
0
˜ 7 sec. MAIN RELAY
K33
ON OFF
4 sec.
BATTERY RELAY
K7
4 sec.
ON OFF 700-1-04-01-23BZ
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-45
CONTROL OF HYDRAULIC DRIVEN FAN 1) Outline of control Main control of hydraulic driven fan is illustrated below. Detailed description for each section is shown after next section. 1) 2) 3) 4) 5)
Fan speed control according to water temperature Spool stick prevention control Engine start/stop control Reversing fan control (cleaning mode) Actual fan speed checking mode
2) Basic circuit configuration
A1
ENGINE CONTROLLER
CONTROLLER
ENGINE TARGET SPEED
THROTTLE VOLUME
R3
5V
b
SIG
CAN-H
GND
CAN-L
1
A2 a
FAN REVERSING SWITCH
S64
5V
ENGINE SPEED ENGINE COOLANT TEMP. FAILURE CODE
FAN MOTOR
MONITOR KEY SWITCH
UART
S1
M9
P1
24V
Y31
M
FAN REVERSING SOLENOIDE VALVE
PNP out
24V
S51
GATE LIMIT SWITCH
LEVER LOCK SOLENOID
Y1
RELAY
Y32 PWM out
ELECTROMAGNETIC PROPORTIONAL VALVE FOR CONTROLLING FAN SPEED
PWM return
P
700.1.04.01.23CA
a) b) 1 A1 A2 R3 S1
Target speed information, Engine speed, engine coolant temperature and failure mode information Engine Computer/ controller Engine controller Throttle volume Key switch
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-46
1. Fan speed control according to water temperature Set the fan rotation at a low speed to prevent over-cooling and carry out quicker warming-up when engine cooling water temperature is low, and conversely, set the fan at a proper speed to realize low noise and low fuel consumption when engine cooling water temperature is high. 1) Outline 1) The controller calculates command current value from the map illustrated below according to engine cooling water temperature transferred from the engine controller through CAN communication circuit and then transfers the command current to «PWM out» (electromagnetic proportional valve for controlling fan speed) so that the fan may rotate at a speed in response to the command current. 2) Judged value of fan speed at the command current value is to be decided only at the maximum and at the minimum rotation (values shown in Fig. below are both at oil temperature of 50°C (122°F)), therefore, the fan speed at medium range varies from fan to fan. 2) Engine cooling water- Command current characteristics ENGINE SPEED (min-1) 1570 +100 0
HIGH IDLING
FAN SPEED
1570
IDLING
COMMAND CURRENT VALUE
REF. VALUE
max.1000 (500)
(mA) 600 550 500 450 400 350 300 250 200 150 100 50 0
RADIATOR COOLANT TEMPERATURE
80
START WORKING
83
85
RANGE
90
95
100
FULL OPEN
105 (˚C)
MAX.COOLING CONDITION
THERMOSTAT FUNCTIONING 700.1.04.01.28BE
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-47 3) Back-up operation 1) When failure code illustrated below appears, it allows the command current supplied from the controller to the electromagnetic proportional valve for control fan speed to be 0 mA. In addition, when failure code illustrated below occurs, the error will not be returned as fan rotation may become unstable due to poor connection and the like. Failure codes related to engine system E0335 : Crank sensor trouble E0340 : G sensor trouble E2104 : CAN-bus trouble E2106 : CAN time-out E0117 : Trouble with water temperature sensor in low voltage E0118 : Trouble with water temperature sensor in high voltage Failure codes related to mechanism E0070 : Key switch error E0090 : CAN communication error 2) When the message «ELEC PROBLEM» is displayed on the monitor due to functioning of «power transistor protection», it allows the command current stated above to be 0mA. 4) Time chart (back-up operation)
START
START
KEY SWITCH ON
ON
OFF
FAILURE CODE ON OFF
BACK UP 600mA PMW out
Fan speed control based on water temperature. Spool stick prevention control.
Fan speed control based on water temperature. Spool stick prevention control.
0mA
700-1-04-01-23CC
2. Spool stick prevention control Spool stick is a phenomenon that the spool with clearance seal is stuck because actuating force of the spool is increased by building-up of fine particles in the oil to the clearance seal when a certain position in the spool is loaded with hydraulic force for a long time. In order to avoid this, following control is carried out. Spool stick prevention control for electromagnetic proportional valve for control fan speed 1) Outline 1) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as started) or more, spool stick prevention current (100mA) is delivered from «PWM out» in the controller at regular intervals (every 1min.) for a certain time (50m sec.). 2) Although the spool stick prevention current is delivered at regular intervals (every 1min.), when command current value obtained by «fan speed control according to water temperature» is larger than that of spool stick prevention current, the control becomes invalid and the spool stick prevention current stated above will not be delivered. (Refer to figure below).
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-48 2) Time chart Invalid range of spool stick prevention
mA) 600
Command current
500 400 300
Fan speed control according to water temperature
1 min 1 min 200 50 msec 100
0
Time
700-1-04-01-23CD
Solenoid valve for reversing fan Spool stick prevention control 1) Outline Engine key ON/OFF mode 1) When the key switch is turned ON and 2 seconds have passed, spool stick prevention signal is delivered from «PNP out» in the controller for a certain period of time (20msec.). 2) When the engine is started within 2 seconds after the key switch has been turned ON, the spool stick prevention signal stated above will not be delivered. 3) Similarly, after the key switch has been turned OFF too, the spool stick prevention signal is delivered from «PNP out» in the controller for a certain period of time (20msec.). 2) Time chart Power-cut delay START KEY SWITCH
ON OFF ON
POWER SUPPLIED TO CONTROLLER OFF 2sec
SOLENOID VALVE FOR REVERSING FAN
20msec
20msec
ON
OFF
800.1.04.01.26IA
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-49
3. Engine start/stop control 1) Engine start control When the engine has been started, lower the fan speed (to restrain surge pressure on discharging side of pump) to carry out following control for easing load in starting engine. 1) Turning the key switch ON allows the controller to supply current of 600mA to «PWM out» (electromagnetic proportional valve for control fan speed). 2) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as started) or more, «PWM out» in the controller shifts to «fan speed control according to water temperature» and «spool stick prevention control». 2) Engine stop control In order to prevent cavitation due to fan rotation by inertia when the engine has been stopped, following control is carried out. 1) Turning the key switch OFF allows the controller to supply current of 600 mA to «PWM out» (electromagnetic proportional valve for controlling fan speed). 2) «PWM out» in the controller keeps on supplying current of 600mA while «Power-cut delay» is functioning. 3) Time chart Power-cut delay START KEY SWITCH
ON OFF
POWER SUPPLIED TO CONTROLLER
ON OFF
SOLENOID VALVE FOR REVERSING FAN
Spool stick prevention control OFF
Judgment of start 300min-1
ENGINE SPEED STOP
600mA
600mA
Fan speed control according to water temperature. Spool stick prevention control.
PWM out 0mA
Fan speed control according to water temperature.
FAN SPEED STOP 700-1-04-01-23CF
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-50
4. Reversing fan control Flowing direction of air is reversed by reversing fan revolution so that trifling dust clogged in the radiator core is possible to be removed. Since heat radiation capacity declines while the fan rotation is being reversed by which overheat of the engine becomes possible, do not operate any control lever. Change over of mode 1) Outline 1) Turning ON fan reversing switch (momentary) after the key switch has been turned ON allows the fan to change rotation from normal mode to reverse mode. During this period, the buzzer gives warning sound of 2Hz from the monitor to inform that the fan is rotated in reverse mode. When the reversing switch is turned ON again, it changes rotation from reverse to normal and the buzzer stops sounding. 2) For reverse mode, previous data are to be reset. This means that turning OFF the key switch in either of mode, reverse or normal, allows it to be operated in normal mode when the key switch is turned ON next time. 3) When warning message «OVER HEAT» is displayed on the monitor, it will not be operated in reverse mode. The fan reversing switch functions and the mode can be switched over after overheated condition is released and warning message «OVER HEAT» is disappeared from the monitor. 4) When the message «ELEC PROBLEM» is displayed on the monitor due to functioning of «power transistor protection», it will not be operated in reverse mode as stated above. 2) Time chart KEY SWITCH FAN REVERSING SWITCH
MODE
ON OFF ON
ON
ON
ON
ON
OFF
Normal
Reverse
Normal
Reverse
Normal
Normal
Reverse
700-1-04-01-23CG
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-51 Function of reversing fan 1) Outline 1) When the fan reversing switch (momentary) is turned ON after the key switch has been turned ON, reversing signal is delivered to the fan reversing solenoid valve to allow the fan to change rotation from normal mode to reverse mode. And at the same time, a signal is transferred to the lever lock relay from «PNP out» in the controller and the lever lock solenoid valve turns OFF. This allows the machine operation to be impossible regardless of where the gate lever is positioned. At this time, command current from «PWM out» in the controller drops from 600mA to 0 mA. 2) Starting the key switch in the situation above allows the engine to be started in fan reverse mode and the fan rotates at maximum speed as the command current value from «PWM out» in the controller is 0 mA. 3) When the key switch is turned OFF in reverse mode, it switches to be operated in normal mode when the key switch is turned ON again because previous data are to be reset. 4) Even if it has set up the auto-idle during reversal operation, an auto-idle dose not function. 2) Time Chart START ON
KEY SWITCH
OFF
FAN REVERSING SWING
ON OFF
SOLENOID VALVE FOR REVERSING FAN OFF (PNP out) LEVER LOCK OFF SOLENOID VALVE (PNP out) MONITOR BUZZER
ON
ON
Normal mode
ON=2Hz sounds
OFF
MODE Max.speed
Max. speed
Normal mode Reverse mode ENGINE SPEED (TARGET PEED)
Low speed Low speed
STOP 600mA(WT< 90˚C)
600mA
PWM out 0mA
Max. speed
FAN SPEED STOP
700-1-04-01-23 CH
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-52
5. Checking mode of actual fan speed The actual fan sped is possible to be checked as the fan speed can be set at any point within a certain range by operation of the switch. 1) Outline 1) Command current of “PWM out” in the controller can be set at any point by 10mA pitch within the range of between 100mA and 600mA at «OUT» in «RST1 (reset)» screen in «Service support indication» (refer to service support items for operation) on the monitor. 2) After «OUT» is selected on the reset screen (refer to figure below) with the buzzer stop switch, displayed figures change every time the travel mode switch is turned ON. Displayed figures show command current and indication immediately after selection is command current value at present. Once the travel mode switch is turned ON, it shows figures «0100» and every time switch is turned ON, the figures change by 10 as illustrated below. ->0100->0110->0120->0130->0140->0150->0550->0560->0570->0580->0590->0600-> Current value at present
3) For confirmed fan rotation check mode, data in last time are reset. That is, even if the key switch has been turned OFF with the current set at a certain value, it will be turned in normal mode when the key switch is turned ON next time. 2) Service support screen
This mode is to be used to check if the fan speed changes according to current variation.
6. Fan speed control according to oil temperature Fan speed control according to oil temperature is added and the temperature of the hydraulic oil is prevented from overheating. 1) Outline 1) The controller adjusts the instruction current value to 0mA more than the temperature shown from the temperature of the hydraulic oil transmitted from the sensor of the temperature of the hydraulic oil in the figure below.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-53 2) Temperature of the hydraulic oil - Command current characteristics
Ref. value
Command current value
Control start point of temperature of oil
Fan speed control according to water temperature
(176
Fan speed control according to oil temperature
(185 (194 Hydraulic oil temp.
(203
(212
(°C) (°F)
450.1.04.01.32A
3) Back-up operation 1) When failure code illustrated below appears, it allows the command current supplied from the controller to the electromagnetic proportional valve for control fan speed to be 0 mA. In addition, when failure code illustrated below occurs, the error will not be returned as fan rotation may become unstable due to poor connection and the like. Failure codes related to mechanism. M0020: Trouble with hydraulic oil temperature sensor in low voltage 4) Time chart (back-up operation)
START
START
ON
ON
KEY SWITCH OFF
FAILURE CODE ON OFF
BACK UP 600mA
PMW out
Fan speed control based on water and oil temperature. Spool stick prevention control.
Fan speed control based on water and oil temperature. Spool stick prevention control.
0mA 700-1-04-01-23CC
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-54
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION 1) Control outline The controller detects fuel quantity by fuel sensor allowing the fuel supply pump to make an automatic stop when the fuel tank is filled up. 2) Circuit configuration
Fuel tank
Battery relay
Fuel sensor
Fuse 20A Battery Rf
Controller
R5
K7
SIG GND
A1
G1
Re
S61 Main relay (for fuel supply pump) (Manual)
(Automatic)
3-position roker switch (*1) Fuel supply pump)
K30 K31
CN6-17(PNP)
Motor BZ
P
M14
GND
(*2) Switch
Relay (automatic) (*1) Fuel supply pump: Made by JABSCO (manufacturer in UK). (*2) Buzzer: Same buzzer used as travelling alarm to MSR.
700-1-04-01-23CK3
*All components other than controller, battery, and fuel level sensor are stored in the tool box (in house in front-right). A1 G1 K7 K30 K31 M14 R5 S61
Computer/controller Battery Relay battery Refuel pump relay Refuel pump stop relay Fuel feed pump motor Fuel sensor Refuel pump switch
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-55 3) Operation 1) Automatic stop 1. Assemble it with the switch built-in the fuel supply pump turned ON. (No control is required for customers.) 2. Put the 3-position rocker switch to Automatic side after the key switch has been turned ON. (Center: OFF, Automatic Alternate: ON, Manual: Momentary ON.) 3. This operation allows electric power to be supplied to the fuel supply pump by way of both relays of «auto» and «main» so that fuel is pumped up into the fuel tank out of an fuel drum. 4. The controller is always monitoring quantity of fuel remained in the tank by using fuel sensor. 5. When the fuel sensor comes to the full level (Rf) position or above, the controller gives output signal to the relay (auto). (NPN output.) 6. The relay (auto) is switched over by the output signal allowing the power supplied to the fuel pump to be shut off. 7. At the same time, the buzzer sounds to inform that refueling has been made an automatic stop. 8. When the 3-position rocker switch is turned OFF, the buzzer stops sounding and automatic refueling mode is released. 9. Even if the automatic refueling mode has been released, the controller keeps on sending output signal to the relay (auto) if the position of fuel sensor is at the full level (Rf) or above. 10. The controller stops giving the output signal to the relay (auto) when the fuel sensor comes down below the full level (Rf) position. 2) Manual refueling 1. In case where automatic refueling fails functioning due to troubles such as in the fuel sensor, the controller, and the relay (auto). 2. In case where a machine cannot fill up the fuel to its full by automatic refueling. 3. Supply fuel while monitoring fuel gauge with the 3-position rocker switch turned to manual side (momentary). 4. Power is supplied to the fuel supply pump via the relay (main) from the manual switch so that fuel can be supplied to the tank.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-56
POWER TRANSISTOR PROTECTION CONTROLLER 24V (PNP) 17
FUEL SUPPLY PUMP
18
FREE SWING (NA) BEACON (EU)
19
TRAVEL ALARM
21
ENGINE STOP (EMERGENCY STOP)
22
HYDRAULIC DRIVEN FAN REVERS
27
SWING BRAKE
28 29
2-SPEED TRAVEL 22
CUSHION
30 31
SWING SHUT-OFF
32
BACKUP 1
20
BACKUP 2
700-1-04-01-23 CL
In the event that a solenoid valve or a relay develops a short circuit, the power transistor output will be shut off in order to protect the controller. A «ELEC PROBLEM» message will be displayed during the failure. Perform the service support check to have the location of failure pinpointed and displayed. Then follow the display result and inspect the wire or the equipment that seems to be experiencing the failure.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-57
MONITOR DISPLAY
3
2
1 CD00E007A2
1. Fuel level indicator 2. Hydraulic oil temperature indicator
3. Coolant temperature indicatora2
Normal Display 1.Radiator coolant temperature 1) Circuit configuration
A1 A2
B1
P4 SCALE
104 122 140 158 176 194 212 230 COOLANT TEMPERATURE
° ° 700-1-04-01-23CN2
A1 Computer/controller A2 Engine controller
B1 Coolant temperature sensor P4 Monitor display
2) Operation 1. Coolant temperature sensor is installed inside the engine. The signal from this sensor (Vtw) will be transmitted to engine controller as an analog signal (voltage). 2. The engine controller converts the transmitted signal into a temperature value. It then transmits this coolant temperature data to the controller via CAN communication. 3. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display level for the signal level. The controller then transmits the data to monitor display via serial communication. 4. When the monitor display receives transmission, it reflects the data received as a bar graph on the display. 5. «OVER HEAT» will be displayed when level 8 lights up on the scale. (The engine does not stop.)
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-58 2. Hydraulic oil temperature 1) Circuit configuration
P4 B2 A1
SCALE
°C 68
86
104
122
140
158
176
194
212
°F
OIL TEMPERATURE
700-1-04-01-23CO
A1 Computer/controller B2 Hydraulic oil temperature sensor
P4 Monitor display
2) Operation 1. Hydraulic oil temperature sensor is installed inside the suction piping. The signal from this sensor (Vto) will be transmitted to controller as an analog signal (voltage). 2. When the controller receives the signal, it first converts it into a temperature value. The controller then uses to the graph shown above to determine the bar graph display level for the signal level. The controller then transmits the data to monitor display via serial communication. 3. When the monitor display receives transmission, it reflects the data received as a bar graph on the display. 4. «OVER HEAT» will be displayed when level 8 lights up on the scale.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-59 3. Fuel level 1) Circuit configuration
P4 B3
A1
700-1-04-01-23 CP2
A1 Computer/controller B3 Fuel temperature sensor
P4 Monitor display
Remaining fuel (L)
Fuel sensor resistance (W)
Input voltage Vf1 (V)
Bar graph
480 <
10 to 18
0.455 to 0.766
8
420 to 480
18 to 24
0.766 to 0.964
7
364 to 420
24 to 30
0.964 to 1.142
6
300 to 364
30 to 37
1.142 to 1.337
5
244 to 300
37 to 46
1.337 to 1.582
4
136 to 244
46 to 61
1.582 to 1.891
3
81 to 136
61 to 75
1.891 to 2.138
2
< 81
75 to 80
2.138 to 2.222
1 (Refill fuel)
2) Operation 1. Fuel sensor is installed inside the fuel tank. The signal from this sensor (Vf1) will be transmitted to the controller as an analog signal (voltage). 2. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display level for the signal level. The controller then transmits the data to monitor display via serial communication. 3. When the monitor display receives transmission, it reflects the data received as a bar graph on the display.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-60
Message Display START
MESSAGES DISPLAYED KEY SWITCH ON
KEY SWITCH AND ENGINE RUNNING
ELEC PROBLEM ALTERNATOR LOW OIL PRESS AIR FILTER
LOW FUEL LOW COOLANT WARNING
YES
NO
OVER HEAT ENG IDLING AUTO WARMUP POWER UP
ENG PRE HEAT SERVICE DUE
MODE DISPLAYS H : SUPER HEAVY MODE S : REGULAR MODE L : FINISHING MODE AUTO : AUTO MODE
TRAVEL MODE DISPLAT I : LOW-SPEED TRAVEL II : HIGH-SPEED TRAVEL AUTO IDLE DISPLAYS ON : AUTO IDLE OFF : ONE-OUCH IDLE 700-1-04-01-23 CQ
Buzzer
Message Display
Meaning and Measures to be Taken
ENG PRE HEAT
Engine warm up (glow) is indicated.
AUTO WARN UP
Indicates automatic warming of the engine. The automatic warming is released by moving the throttle volume or operation levers.
ENG IDLING
Indicates the engine is running at low idling.
POWER UP
Indicates the system is in automatic digging power up.
SERVICE DUE
At the time of every 500 hour service intervals, one minute indication appears for 5 times when the engine starts.
Sounds
LOW FUEL
Sounds
LOW COOLANT
Indicates the coolant water level is low. Add coolant water.
Sounds
LOW OIL PRESS
Indicates the engine oil pressure is abnormally low. Stop the engine, check engine oil level and add oil.
Sounds
OVER HEAT
Sounds
ALTERNATOR
Sounds
ELEC PROBLEM
Sounds
AIR FILTER
Lep SC4604001-0EN
Indicates the fuel level is very low. Add fuel.
Indicates the engine coolant temperature or hydraulic oil temperature abnormally rises. Put the engine in low idling and reduce water or oil temperatures. Check the radiator & oil cooler. Indicates problems in battery charging system. Check the electric circuit. Indicates electric problems (short circuit or disconnection) in the electric system. Check the electric circuit. Indicates the air filter clogged. Air filter are cleaned or exchanged promptly.
Issued 03-07
Copyright © 4001-61
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) Access to monitor displays Normal display
A
H Status display
Machine
I information
(a)
Service support display
B
(b) Diagnostic trouble
B B
Usage history
B Reset
E
D B CHK7
B
F
C CHK1 C
CHK5
CHK2
G
C
CHK6
CHK3 C CHK4 C CHK5 C
DIAG1
HR 12
C DIAG2
C D
C DIAG3
C D
C
HR 9
C
C D
C DIAG6
HR 10 C
DIAG4
DIAG5
HR 11
HR 8 C
D
HR 7
C
HR 1
RST1
C HR 2
RST2 J
C HR 3 C HR 4 C HR 5 C HR 6 C
RST11 C RST12 C RST13 C RST14 C RST15 C RST16 C 800.1.04.04.08A
a) Bar graph (Hydraulique oil temperature, coolant temperature, fuel level) b) Mode (Travel, work, auto, idle)
Operating Switches A. B. C. D.
E.
To be switched after the travel & work mode switch has been turned ON for more than 3 seconds. To be switched when the auto mode switch is turned ON. To be switched when the buzzer stop switch is turned ON. Data is to be cleared after the work mode switch has been turned ON for more than 10 seconds (buzzer sounds when the data have been cleared). Reset function is to be selected when the buzzer stop switch is turned ON, the selected function is to be reset when the travel mode switch is turned ON, and the data are to be reset after the work mode switch has been turned ON for more than 10 seconds (buzzer sounds when the data have been reset).
Lep SC4604001-0EN
F. G. Output with the protection circuit actuated is to be checked when the travel mode switch is turned ON. H. Automatic detection of short circuit is to be indicated after the travel mode switch has been turned ON for more than 10 seconds. I. To be switched after the auto mode switch has been turned ON for more than 10 seconds. J. Selected machine model is be cleared after the auto mode switch has been turned ON for further 10 seconds (buzzer sounds when it has been cleared). K. To be switched after the one-touch idle switch has been turned ON for more than 10 seconds at anytime while the service support screen is being displayed.
Issued 03-07
Copyright © 4001-62
Machine condition 1. Machine condition CHK1 CHK
MODE II H
ENG
2000
rpm
1 P1
030.0
MPa
I
0300
mA
P2
030.0
MPa
WT
0080
°C
MODE: P1: P2: N: ENG: I
N
03.00
MPa
OT
0055
°C
WT: OT:
Travel - work Main pump (P1) pressure Main pump (P2) pressure Negative pressure (N) Engine rpm Pump control current value Fan motor current value (when Travel Mode switch ON)) Radiator coolant temperature Hydraulic oil temperature Intake air temperature (only when Travel Mode switch ON))
2. Machine condition CHK2 CHK
MODE II H
TR1
2 R
0080
%
TR2
R:
Engine load ratio
FT:
Fuel temperature Boost temperature (only when Travel Mode switch ON)
TV: TR1 TR2 TR3 TR4
Throttle volume degree of opening Controller transistor output Controller transistor output Controller transistor output Controller transistor output
0000 0000
FT
0000
°C
TR3
0000
TV
0100
%
TR4
0000
Transistor output: «0» = OFF; «1» = ON TR1 0 0 0 0
TR2 0 0 0 0
TR3 0 0 0 0
Swing brake
X
Free swing (NA)
2-speed travel
Soft/hard (EU,NA)
Engine stop
Travel alarm
Swing shutoff
reverse(CX460to800, E805)
Boosting
High dump(CX700/800, E805)
Lift (LBX-MH)
Hyd Fan reverse
TR4 0 0 0 0 Fuel supply pump (EU) X X Drop (LBX-MH)
X: Not used
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-63
3. Machine condition CHK3 SW1 to SW3 CHK
MODE II H
SW4
0000
SW4 to SW7
3 SW1
0000
SW5
0000
SW2
0000
SW6
0000
SW3
0100
SW7
0000
Controller switch input (sensor switch) Controller switch input (operation switch)
Pressure switch electronic control box switch inputs: «0» = OFF; «1» = ON SW1 0 0 0 0
SW2 0 0 0 0
SW3 0 0 0 0
Attachment press. SW
Air cleaner
Battery charge
Travel press. SW
Coolant SW
Engine stop
Swing press. SW
2nd auxiliary press. SW
Drop (LBX-MH)
Auxiliary pressure SW
Boom up press. SW
Lift (LBX-MH)
SW4 0 0 0 0
SW5 0 0 0 0 Soft/hard (EU, NA)
SW6 0 0 0 0 Swing lock
Windshield washer Alarm change
Free swing (NA)
Emergency stop
(EU, NA)
High dump (CX700/800, E805)
Working lamp
Breaker mode
One-touch idle
Wiper
L/M mode
SW7 0 0 0 0 Anti-theft protection Key switch Fan reverse(CX460 to
800; E805) X
X = Not used
4. Machine condition CHK4 CHK
MODE I H
TG
0000
rpm
BP
0000
MPa
4
(Ω)
FS
0080
AC
0005
SP1
0000
TR5
0010
SP2
0000
FS: AC: TR5: TG: BP:
AC
SP1 SP2
Fuel sensor resistance A/C control temperature Engine oil pressure Target engine speed Boom bottom pressure (Europe only) Overload alarm pressure display (only when beacon switch ON) Atmospheric pressure Boost pressure
0 0 0 4 1: below 30°C 2: between 30°C and 45°C 3: between 45°C and 65°C 4: between 65°C and 75°C
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-64 Setting of unit fir each shipping territory
NOTE: Below a decimal point is not displayed but it is as fallows.
TR5, SP1, SP2 Default
When switched
Japan
kPa
kgf/cm2
Export
kgf/cm2
kPa
North America
psi
kPa
Europe
kPa
-
. . .
kPa kgf/cm2 psi
800.1.04.04.08D
5. Machine condition CHK5 CHK
MODE II H
TR1
0001
R FT TV
5 R
0080
%
TR2
0001
TR1
FT
0000
°C
TR3
0000
TR2
TV
0100
%
TR4
0000
1. While the travel mode switch is ON on the «CHK2» screen, the output status when over-current has been detected in the past is displayed.
TR3 TR4
Engine load ratio Fuel temperature Throttle volume degree of opening Transistor output status when over-current detected Transistor output status when over-current detected Transistor output status when over-current detected Transistor output status when over-current detected
2. Data is cleared by resetting the trouble code on the trouble diagnosis screen. 3. The example in the figure above shows that a travel alarm, swing braking, and battery relay output were being carried out when over-current was detected.
6. Machine condition CHK6 CHK
MODE II H
TR1
0010
6 R
0080
%
TR2
0000
FT
0040
°C
TR3
0000
TV
0100
%
TR4
0000
TR3 TR4
Results of automatic short detection Results of automatic short detection
4. This data is cleared when the key switch is switched OFF. * For CHK1 to 6, the units can be switched with the work lamp switch. Status held as is when key OFF
1. Shorts are automatically detected if the key switch is switched ON while the one-touch idle switch is ON.(* The engine must not be running.) 2. If you switch to the «CHK2» screen and switch the travel mode switch ON for 10 seconds, the automatic detection results are displayed. 3. The example in the figure above shows that the 2speed travel line is currently shorted. R FT TV TR1 TR2
Engine load ratio Fuel temperature Throttle volume degree of opening Results of automatic short detection Results of automatic short detection
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-65
Diagnostic code 2. Detection of engine failures DIAG1 to 6 1) Trouble diagnosis (DIAG1), Engine system current trouble status (trouble code) DIAG
MODE II H
E
0000
E
0118
E
0000
E
0000
E
0000
E
0000
E
0000
E:
1
Example
Engine system trouble code For the engine error code list, refer to Page 68 Water temperature sensor abnormality
2) Trouble diagnosis (DIAG2), Engine system past trouble status (trouble code) DIAG
MODE II H
E
0000
E
2106
E
0000
E
0000
E
0000
E
0000
E
0000
E: Example
Engine system trouble code CAN time-out abnormality
2
3) Trouble diagnosis (DIAG2), Engine system past trouble status (time of trouble: controller hour meter value) E: DIAG
MODE II H
E
0000
Example
3 E
0200
E
0000
E
0000
E
0000
E
0000
E
0000
1. Switching the work mode switch ON for longer than 10 seconds clears the data on past trouble codes and their times of occurrence. 2. The time displayed with «DIAG3» is the time at which the first trouble code occurred after the data was cleared. (The times for the second and subsequent trouble codes are not recorded.) 3.
Lep SC4604001-0EN
Engine system trouble code trouble code. CAN time-out abnormality: Abnormality occurred at 200 hours
When the data is cleared, the «DIAG2» and «DIAG3» data is stored into EEPROM.
Issued 03-07
Copyright © 4001-66 4) Trouble diagnosis (DIAG5), Machine main unit system Current trouble status (trouble code) DIAG
MODE II H
M
0000
M
0020
M
0000
M
0000
M
0000
M
0000
M
0000
M: Example
Machine main unit system trouble code Oil temperature sensor abnormality
4
M0000: M0010: M0020: M0030: M0040: M0050: M0060: M0070: M0080: M0090: M00A0: M00B0: M00C0: M00F0 M00F1 M00F2 M00F3 M00F4 M00F5
No defect Transistor output short Oil temperature sensor Fuel surface sensor Pressure sensor (P1) Pressure sensor (P2) Pressure sensor (N) Key switch Pressure switch (attachments or travel) CAN communications error Controller reset Engine controller mismatch Boom pressure sensor (Europe) Overheat (at cooling water temperature of over 105°C (221°F) Overheat (at cooling water temperature of over 110°C (230°F) Overheat (at cooling water temperature of over 120°C (248°F) Overheat (at cooling water temperature of over 80°C (176°F) Overheat (at cooling water temperature of over 90°C (194°F) Engine oil pressure drop (at pressure of below 40kPa
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-67 5) Trouble diagnosis (DIAG5), Machine main unit system Past trouble status (trouble code) M: DIAG
MODE II H
M
0000
Example
5 M
0020
M
0000
M
0030
M
0000
M
0000
M
0000
Machine main unit system trouble code Oil temperature sensor abnormality, fuel sensor abnormality
6) Trouble diagnosis (DIAG6), Machine main unit system Past trouble status (time of trouble: controller hour meter value) M: DIAG
MODE II H
M
0000
6
Example M
2000
M
0000
M
1000
M
0000
M
0000
M
0000
Machine main unit system trouble code Oil temperature sensor abnormality: Abnormality occurred at 2000 hours Fuel sensor abnormality: Abnormality occurred at 1000 hours
1. Switching the work mode switch ON for longer than 10 seconds clears the data on past trouble codes and their times of occurrence. 2. The time displayed with «DIAG6» is the time at which the first trouble code occurred after the datawas cleared. (The times for the second and subsequent trouble codes are not recorded.) 3.
Lep SC4604001-0EN
When the data is cleared, the «DIAG5» and «DIAG6» data is stored into EEPROM.
Issued 03-07
Copyright © 4001-68 7) Engine error code list Engine Type Trouble code
Trouble contents 4H
6H
6U/ 6W
Monitor display
Restoration from troubles
0087
No pump pressure send (fuel leak)
O
O
O
ELEC PROBLEM
1
0088
Common rail pressure abnormality (1st stage. 2nd stage)
O
O
O
ELEC PROBLEM
1
0089
Common rail pressure abnormality (pump overpressure send)
O
O
O
ELEC PROBLEM
1
0090
SCV drive system cut line, +B short, ground short PCV1 drive system cut line or ground snort
O
O
O
ELEC PROBLEM
2
0092
PCV1 drive system +B short
--
--
O
ELEC PROBLEM
1
0107
Atmospheric pressure sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
2
0108
Atmospheric pressure sensor abnormality (high voltage abnormality)
O
O
O
ELEC PROBLEM
2
0112*
Intake air temperature sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
2
0113*
Intake air temperature sensor abnormality (high voltage abnormality)
O
O
O
ELEC PROBLEM
2
0117*
Water temperature sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
2
0118*
Water temperature sensor abnormality (high voltage abnormality)
O
O
O
ELEC PROBLEM
2
0182*
Fuel temperature sensor abnormality (low voltage abnormality)
O
O
O
--
2
0183*
Fuel temperature sensor abnormality (high voltage abnormality)
O
O
O
--
2
0192
Common rail pressure sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
2
0193
Common rail sensor abnormality (high voltage abnormality)
O
O
O
ELEC PROBLEM
2
0201
Injection nozzle #1 drive system open line
O
O
O
ELEC PROBLEM
1
0202
Injection nozzle #2 drive system open line
O
O
O
ELEC PROBLEM
1
0203
Injection nozzle #3 drive system open line
O
O
O
ELEC PROBLEM
1
0204
Injection nozzle #4 drive system open line
O
O
O
ELEC PROBLEM
1
0205
Injection nozzle #5 drive system open line
--
O
O
ELEC PROBLEM
1
0206
Injection nozzle #6 drive system open line
--
O
O
ELEC PROBLEM
1
0219
Overrun
O
O
O
ELEC PROBLEM
2
0237
Boost pressure sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
2
0238
Boost pressure sensor abnormality (nigh voltage abnormality)
O
O
O
ELEC PROBLEM
2
0335/ 0336
Crank sensor abnormality (no signal, abnormal signal)
O
O
O
ELEC PROBLEM
1
0340/ 0341
Cam (G) sensor abnormality (no signal, abnormal signal)
O
O
O
ELEC PROBLEM
1
0380
Glow relay abnormality
O
O
O
ELEC PROBLEM
1
0487
EGR position sensor abnormality
O
O
O
ELEC PROBLEM
1
0488
EGR valve control abnormality
O
O
O
ELEC PROBLEM
2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-69 Engine Type Trouble code
1 2
3
Trouble contents 4H
6H
6U/ 6W
Monitor display
Restoration from troubles
0522
Engine oil pressure sensor abnormality (low voltage abnormality)
O
O
O
ELEC PROBLEM
1
0523
Engine oil pressure sensor abnormality (high voltage abnormality)
O
O
O
ELEC PROBLEM
2
0601
ROM abnormality
O
O
O
ELEC PROBLEM
2
0603
EEPROM abnormality
O
O
O
ELEC PROBLEM
2
0606
CPU abnormality
O
O
O
ELEC PROBLEM
2
0611
Charge circuit 1 abnormality
O
O
O
ELEC PROBLEM
2
0612
Charge circuit 2 abnormality
O
O
O
ELEC PROBLEM
2
1093
No pump pressure send (2nd stage)
--
--
O
ELEC PROBLEM
1
1095
Pressure limiter open
O
O
O
ELEC PROBLEM
1
1112*
Boost temperature sensor abnormality (low voltage abnormality)
O
O
O
--
2
1113*
Boost temperature sensor abnormality (high voltage abnormality)
O
O
O
--
2
1173
Overheating
O
O
O
--
2
1261
Injection nozzle common 1 drive system abnormality
O
O
O
ELEC PROBLEM
1
1262
Injection nozzle common 2 drive system abnormality
O
O
O
ELEC PROBLEM
1
1291
PCV2 drive system cut line or ground short
--
--
O
ELEC PROBLEM
2
1292
PCV2 drive system +B short
--
--
O
ELEC PROBLEM
1
1345
Cam (G) sensor out of phase
O
O
O
ELEC PROBLEM
1
1625
Main relay system abnormality
O
O
O
ELEC PROBLEM
2
1630
A/D conversion abnormality
O
O
O
ELEC PROBLEM
2
1631
5V power supply 1 voltage abnormality
O
O
O
--
2
1632
5V power supply 2 voltage abnormality
O
O
O
ELEC PROBLEM
2
1633
5V power supply 3 voltage abnormality
O
O
O
ELEC PROBLEM
2
1634
5V power supply 4 voltage abnormality
O
O
O
ELEC PROBLEM
2
1635
5V power supply 5 voltage abnormality
O
O
O
ELEC PROBLEM
2
2104
CAN bus abnormality
O
O
O
ELEC PROBLEM
2
2106
CAN time-out abnormality
O
O
O
ELEC PROBLEM
2
Item marked with «O» in the table means that it can be applied. Restoration from troubles. There are 2 ways as illustrated below to restore it from troubles. In order to clear an error code depending on circumstances, control of main switch is necessary as follows: 1) Turn ON the key switch to start the engine, hold the switch for 10 second as it is turned ON, and then turn it OFF to restore it to be normal. 2) Turn ON the key switch, hold the switch for 10 second as it is, and then turn it OFF to restore it to be normal For temperature sensors marked with «*» in the table however, hold the key switch for 3 minutes after it has been turned ON, then turned it OFF.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-70
Machine history 1. Screen HR1 ENG WRK U T S PU BRK
: Hour meter (alternator generation time) : Machine operation time (attachment ON or travel ON) : Attachment operation time : Travel operation time : Swing operation time : Boost time : Breaker usage time
H S L A WT OT FT
: H mode usage time : S mode usage time : L mode usage time : A mode usage time : Maximum coolant temperature : Maximum hydraulic oil temperature : Maximum fuel temperature
1 2 3 4 5
: Controller power supply ON time : 1-speed mode usage time : 2-speed mode usage time : Travel hydraulic only time : Maintenance time
6
: *****
7
: *****
2. Screen HR2
3. Screen HR3
4. Screen HR4 [P1 pressure distribution] 1 : Time P1 10 MPa or less 2 : Time P1 10 to 15 MPa 3 : Time P1 15 to 20 MPa 4 : Time P1 20 to 25 MPa 5 : Time P1 25 to 30 MPa 6 : Time P1 30 to 25 MPa 7 : Time P1 35 MPa
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-71
5. Screen HR5 [P2 pressure distribution] 1 : Time P2 10 MPa or less 2 : Time P2 10 to 15 MPa 3 : Time P2 15 to 20 MPa 4 : Time P2 20 to 25 MPa 5 : Time P2 25 to 30 MPa 6 : Time P2 30 to 35 MPa 7 : Time P2-35 MPa
6. Screen HR6 [Engine speed distribution] 1 : Time N 1175 min-1 or less 2 : Time N 1175 to 1375 min-1 3 : Time N 1375 to 1575 min-1 4 : Time N 1575 to 1775 min-1 5 : Time N 1775 to 1975 min-1 6 : Time N 1975 to 2175 min-1 7 : Time N 2175 min-1 or more
7. Screen HR7 [Coolant temperature distribution] 1 : Time TW 77°C or less (Marks 1 and 2 on the bar graph) 2 : Time TW 77 to 82°C (Mark 3 on the bar graph) 3 : Time TW 82 to 97°C (Mark 4 on the bar graph) 4 : Time TW 97 to 100°C (Mark 5 on the bar graph) 5 : Time TW 100 to 103°C (Mark 6 on the bar graph) 6 : Time TW 103 to 105°C (Mark 7 on the bar graph) 7 : Time TW 105°C or more (Mark 8 on the bar graph)
8. Screen HR8 [Hydraulic Oil temperature distribution] 1 : Time TO 45°C or less (Marks 1 and 2 on the bar graph) 2 : Time TO 45 to 60°C (Mark 3 on the bar graph) 3 : Time TO 60 to 80°C (Mark 4 on the bar graph) 4 : Time TO 80 to 88°C (Mark 5 on the bar graph) 5 : Time TO 88 to 95°C (Mark 6 on the bar graph) 6 : Time TO 95 to 98°C (Mark 7 on the bar graph) 7 : Time TO 98°C or more (Mark 8 on the bar graph)
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-72
9. Screen HR9 [Fuel temperature distribution] 1 : Time TF 30°C or less 2 : Time TF 30 to 40°C 3 : Time TF 40 to 50°C 4 : Time TF 50 to 60°C 5 : Time TF 60 to 70°C 6 : Time TF 70 to 80°C 7 : Time TF 80°C or more
10. Screen HR10 [Load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more
11. Screen HR11 [H mode high idle load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more
12. Screen HR12 [S mode high idle load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more Switching any of the work mode switches for the HR1 to 12 display ON for longer than 10 seconds clears all the usage history data.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-73
Resetting Resetting (RST1, 2) MODE BRK L/M AI PA AU HLD OUT
: Travel mode, work mode : Breaker engine speed set : Lifting magnet engine speed set : Auto idle time set (1 to 30 sec.) : Pump output adjustment : Automatic boost rise : Engine protection function : Previous data hold set : Oil pressure drive fan inspection mode
1) Breaker speed set
1 2
3 4
Select the breaker speed set (BRK) with the Buzzer Stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) Now, set the breaker speed (BRK) to 1800 min-1. While watching the monitor, adjust the engine speed with the throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer sound to indicate that the settings have been memorized. Switch OFF the key switch. To check, see the «CHK1» engine speed.
2) Lifting magnet speed set
1 2
3 4
Select the lifting magnet speed set (L/M) with the buzzer stop switch. (The selected item switches from light-ondark display to dark-on-light display.) Now, set the lifting magnet speed (BRK) to 2000 min-1. While watching the monitor, adjust the engine speed with the throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer sound to indicate that the settings have been memorized. Switch OFF the key switch. To check, see the «CHK1» engine speed.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-74
3) Auto idle time change
1 2
3
Select the auto idle time change (AI) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) Now, set the auto idle time to 10 seconds. Turn ON the travel mode switch untl the number reaches 10. The number increases each time the switch is switched ON and can be set from 1 to 30. When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sound to indicate that the settings have been memorized. Turn OFF the key switch.
4) Pump output change PA=0000 PA=0001 PA=0002 PA=0003
: : : :
Normal output mode Low output mode 1 (-100 mA) Low output mode 2 (-150 mA) Low output mode 3 (-200 mA)
1
Select the pump output adjustment (PA) with the buzzer stop switch. (The selected item switches from light-ondark display to dark-on-light display.) 2 Now, set the pump output to low-output mode. Turn ON the travel mode switch so that the number reaches 1, 2, or 3. Each time the switch is switched ON, the number displayed moves to the next step in the sequence 0, 1, 2, 3, …… When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that the settings have been memorized. 3 Switch OFF the Key switch.
5) Automatic pressure rise release setting AU 0 0 0 0 Automabic boost rise (0=ON, 1=OFF) Engine protection function (0=ON, 1=OFF) ***** *****
1 2
3
Select the automatic boost rise release and engine protection function release (AU) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) Now, set the automatic boost rise engine protection fanction to none. Turn ON the travel mode switch so that the number reaches 1. Each time the switch is switched ON, the number displayed moves to the next step in the sequence: 0000 ->0001 ->0010 ->0011 ->0000. When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzuer sounds to indicate that the setteings have been memorized. Turn OFF the key switch.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-75
6) Previous data hold condition change
Auto mode (0 = default setting, 1 = previous data held) Work mode (0 = default setting, 1 = previous data held) Travel mode (0 = default setting, 1 = previous data held) *****
1 2
Select the previous data hold (HLD) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) Now, set the work mode to previous data hold. Switch the travel mode switch ON so that the number reaches 1. Each time the switch is switched ON, the number displayed moves to the next step in the sequence: 0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111 700-1-04-04-07BJ2
3
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce that the storing the setting into memory is complete. Switch OFF the key switch.
7) Hydraulic drive fan inspection mode (only for specifications with hydraulic drive fan)
1 2
Select the previous data hold (OUT) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) The number displayed shows the command current value. The display immediately after the selection is the command current value. When the travel mode switch is turned ON once, the display becomes «0100» and each time the switch is turned ON, the value displayed moves to the next step in the sequence: ->0100->0110->0120->0130->0140->0150->->0160->0170->0180->0190->0580->0590->0600-> Current value at present ->
3 For the hydraulic drive fan inspection mode, the previous time's data is reset. In other words, even if the key switch is switched OFF with some current value set, the next time the Key switch is switched ON, the mode is normal mode.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-76
8) Maintenance time setting
1 2
3
Move to RST2 with the buzzer stop switch and select (2). (The selected item switches from light-on-dark display to dark-on-light display.) The number displayed shows the time for displaying «Maintenance time». The display immediately after the selection is the default maintenance time. Each time the travel mode switch is turned ON, the number displayed moves one step through the cycle «0050->0250->0500-> 1000-> 2000-> 5000-> 0050-> 0250…». When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that the settings have been memorised. Turn OFF the key switch.
* If the buzzer stop switch is held ON for 20 seconds, the time until maintenance display (1) is reset.
9) Injector test mode
1 2
3
Move to RST2 with the buzzer stop switch and select (3). (The selected item switches from light-on-dark display to dark-on-light display.) Now, after the engine has been started, injector test mode is to be set here. Turn ON the travel mode switch so that the number reaches 1. The number toggles between 0 and 1 each time you switch ON the switch. When the number reaches 1, the engine speed is fixed at 500 min-1. For the injector test mode, the previous time's data is reset. In other words, even if the key switch is turned OFF with a value set, the next time the Key switch is turned ON, the mode is normal mode.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-77
MACHINE INFORMATION Setting of machine model The excavator model is selected after re initialising the machine code or replacing an electronic control box. 1. Key switch ON, the screen below appears and «?» for machine is selected:
MACHINE: SH TERRITORY:? CONT. P / N
?
-4
MACHINE MODEL
SH0120
CX130
SH0150
CX160
SH0180
Not used
SH0200
CX210
SH0220
CX240
SH0250
CX290
SH0300
CX330
SH0400
CX460
SH0700
CX700
SH0800
CX800/E805
MACHINE: SH0300- 4
Lep SC4604001-0EN
T° unit
3
EUROPE
MPa
°C
4
Rest of world
KgF
°C
5. Press the work mode switch. The screen below appears and «?» for language is selected.
MACHINE: SH0300- 4 TERRITORY: 3 CONT. P / N
LANGUAGE: ? KHR3320
6. Press the travel mode switch to display the required language code: 0 = Japanese 1 = English 2 = Thai 3 = Chinese 4 = German 5 = French 6 = Italian 7 = Spanish 8 = Portuguese 9 = Dutch 10 = Danish 11 = Norwegian 12 = Swedish 13 = Finnish 14 = Icons
MACHINE: SH0300- 4
KHR3320
MACHINE: SH0300- 4
CONT. P / N
Pressure unit
LANGUAGE:?
3. Press the work mode switch. The screen below appears and «?» for territory is selected.
TERRITORY: ?
Destination
KHR3320
MACHINE CODE
CONT. P / N
Destination code
LANGUAGE:?
2. Press the travel mode switch until the required machine code is displayed.
TERRITORY:?
4. Press the travel mode switch until the required destination code is displayed.
LANGUAGE:?
TERRITORY: 3 CONT. P / N
LANGUAGE: 5 KHR3320
Example: The screen above corresponds to a CX330 model excavator for Europe in French.
KHR3320
Issued 03-07
Copyright © 4001-78 7. After selecting the machine code, the destination code and the language code, press the auto mode switch and the screen below will appear:
10. To confirm the excavator model selection, press the auto mode switch for 10 seconds: The screen below will appear
MACHINE: SH0300- 4 TERRITORY: 3
LANGUAGE: 5
CONT. P / N
CS00F533
KHR3320
11. Press the auto mode switch again and the work screen will appear:
Then the work screen is displayed:
CS00F521 CS00F521
8. If the machine code does not correspond to the engine controller installed, the error code: «E. CONT. ERROR» appears on the screen and the audible warning device sounds.
MACHINE: SH0300- 4 TERRITORY: 3
12. Re-initialising the data In the excavator model selection screen, if the auto mode switch is pressed for 10 seconds, all the data will be erased and the audible warning device will sound. If the key switch is turned OFF and then ON, the screen below will appear and the procedure starts again from the beginning.
LANGUAGE: 5 MACHINE: SH
CONT. P / N
?
-4
KHR3320 TERRITORY:?
LANGUAGE:?
E. CONT. ERROR CONT. P / N
KHR3320
9. Check that the machine code corresponds to the engine controller installed on the excavator. - If the machine code is wrong, start the procedure again from the beginning. - If the engine controller installed is not correct, change it.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-79
Changing the language code
Re-setting of engine information
Display the excavator model confirmation screen (press the auto mode switch for 10 seconds). To change the language code, press the travel mode switch to display the required code. To confirm the language code, press the work mode switch and the audible warning device sounds. Turn the key switch to OFF.
CHK
MODE
,S
7
4
0060
1
0089
5
4005
2
8008
6
0000
3
9543
7
0A79 800.1.04.04.08H
MACHINE: SH0300- 4 TERRITORY: 3
RST MODE
LANGUAGE: 1
CONT. P / N
KHR3320
1 2 3
Example: In the screen opposite, the language code has changed from 5 (French) to 1 (English).
Display of engine information
Injector number Selection places when entering ID code
a i q
b j r
c k s
d l t
4 5 6 7
e m u w
f n v x
g o 0 0
h p 0 0
Ab: Engine code C to x: QR code * 2 places of figure on the left both at the 6th and the 7th lines are fixed to 0. Example:
CHK
MODE
,S
7
4
0060
1
0089
5
4005
2
8008
6
0000
3
9543
7
0A79
ID code
ID code 5 5 3 A 6 B1 8 361 F 3017 194 4 5200 0000 4F
800.1.04.04.08H
Example: Engine controller (ECM) number Engine serial number Q adjustment number
898008-9543 604005 A79
Injector
Engine controller (ECM) number: A to J * 2 places of figure on the left at the 1st line are fixed to 0. 1 2 3
0 0 A C D E G H I
B F J
Engine serial number: K to P * 2 places of figure on the left at the 4th line are fixed to 0. 4 5
0 0 K L M N O P
Q adjustment number: Q to S * 1 place of figure on the left at the 7th line is fixed to 0. 7
0
800.1.04.04.08L-1
List of engine code-machine models applied. ab 55 5B 63
Engine code 6HK1 6UZ1 6WG1
4 5 6 7
Machine models CX330, CX350 CX460 CX700/800, E805
1st line
4th line
2nd line
5th line
3rd line
6th line 7th line
Q R S 800.1.04.04.08L-2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-80
Selection of injector (for checking ID code entered) RST
MODE Hi ,S
11
4
6B18
1
553A
5
3017
2
361F
6
5200
3
1944
7
4F00
RST11 RST12 RST13 RST14 RST15 RST16
: Injector number 1 : Injector number 2 : Injector number 3 : Injector number 4 : Injector number 5 : Injector number 6
1 Select an injector number (RST11 ->RST12 . . . ->RST116) intending to check or enter with the buzzer stop switch. 2 The injector number on the fan side is assigned as 1 and the one on the pump side as 6 (refer to the figure below). Fan
Engine
Pump
800.1.04.04.08K1
Remarks: 1 2 3 4
Engine information re-setting screen will appear from any service support screen by turning the one-touch idle switch ON for more than 10 seconds. Once you have entered the engine information re-setting screen, you cannot exit the screen until the key switch is turned OFF. While the engine is running, you cannot access the engine information re-setting screen even if the remarks "1" above has been carried out. Although the engine can be started while the engine information re-setting screen is being displayed, the ID code cannot be entered.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-81
Entering injector ID code (after injector has been replaced) RST
MODE Lo,S
11
4
6B18
1
553A
5
3017
2
361F
6
5200
3
1944
7
4F00
MODE Hi MODE Lo
: Upper 2 places of figure on each line : Lower 2 places of figure on each line
Injection ID code
800.1.04.04.08L.2
1 Select the replaced injector number 1 (RST11) with the buzzer stop switch. 2 Each time the auto mode switch is turned ON, 2 places of figure to be selected will shift in the order of "1Hi ->1Lo >2Hi -> 2Low -> 3Hi -> 3Lo -> 4Hi -> 4Lo -> 5Hi -> 5Lo -> 6Hi -> 7Hi -> 1Hi . . ." . (Selected line will change from "light-on-dark" to "dark-on-light" indication.) 3 Keep on entering the ID code and enter lower 2 places of figure on 2nd line here. (At this time, the 2nd line is indicated "light-on-dark "and the mode shows "Lo".) For setting the upper place of 2 places, since the figure shifts in the order of "0 -> 1 -> 2 . . . 9-> A -> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON, select "1" here. For setting the lower place of 2 places, since the figure shifts in the order of "0 -> 1 -> 2 . . . 9 -> A -> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON, select "F" here. 4 Check that any line does not indicate "light-on-dark " after completion of entering all ID codes by repeating steps 2) and 3) above, then turn the work mode switch ON for more than 10 seconds to allow data communication with the engine controller (ECM). The buzzer sounds when the data have been written correctly. NOTE: The buzzer will not sound in case where any one of figures has been mistakenly entered. When the key is turned OFF without sounding the buzzer, the ID codes already memorized remain unchanged. 5 Turn OFF the key switch. 6 Access the engine information setting screen again to check that the data have been rewritten correctly.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-82
Entering sheet of ID code of injector Example:
Injection N° 2 ID code
ID code 5 5 3 A 6 B1 8 361 F 3017 194 4 5200 0000 4F
800.1.04.04.080-3
Injection N° 3 Injector
800.1.04.04.08L-1
Fan
Engine
Pump 800.1.04.04.080-4
Injection N° 4
800.1.04.04.08K-1
Injection ID code
800.1.04.04.080-5
Injection N° 5
800.1.04.04.08K-1
Injection N°
800.1.04.04.080-6
Injection N° 6 800.1.04.04.080-1
Injection N° 1
800.1.04.04.080-7
800.1.04.04.080-2
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-83
TROUBLESHOOTING Prior inspections Item
Value
Action
---------------
Add fuel Clean, drain Fill with fluid Drain, clean Fill with oil Fill with oil Fill with coolant
-------
Tighten or replace Tighten or replace Tighten or replace
POINTS TO BE CHECKED WHEN STARTING Lubricants - Coolants 1. Check the quantity of fuel 2. Check that fuel is not contaminated 3. Check the quantity of hydraulic fluid 4. Inspect the hydraulic fluid filter 5. Check the quantity of oil in each reduction gear 6. Check the quantity of engine oil 7. Check the quantity of coolant Electrical equipment 8. Check the battery terminals and wiring for tightness and corrosion 9. Check the alternator terminals and wiring for tightness and corrosion 10. Check the starter motor terminals and wiring for tightness and corrosion OTHER POINTS TO CHECK Hydraulic system - Mechanical equipment 11. Abnormal noise or smell 12. Check for oil leaks 13. Air in the system
-------
Repair Repair Bleed the air
Electrical system - Electrical equipment 14. 15. 16. 17. 18.
Check the battery voltage (with the engine shut down) Check the quantity of fluid in the battery Make sure that the cables are not discoloured, burnt or stripped Check for missing or loose cable retaining clips Check for damp on cables (especially on connectors and terminals)
19. Check fuses for condition and corrosion 20. Check the alternator voltage (with the engine speed above the throttle mid-point) (when battery charge is insufficient, there can be 25 V only at start up) 21. Noise from relay battery (with starter motor ON or OFF)
Lep SC4604001-0EN
23-26 V ----------27.5-29.5 V
---
Replace Add or replace Replace Repair Disconnect and dry if damp Replace Replace
Replace
Issued 03-07
Copyright © 4001-84
Reading the organisation charts Error code and description of problem The error code and the description of the problem are shown in the organisation charts. Error code
Description of the problem
1
The message is still displayed even after refuelling
2
The message is still displayed even after adding coolant solution
Prior checks
Wire colour
Before identifying the cause of the problem, always make prior checks.
When troubleshooting, refer to the table below for the wire colours. (For connector numbers, refer to the following pages).
How to proceed After checking or measuring the items described in one step, depending on the results, choose YES or NO and pass on to the next step. The description in the YES or NO branches refers directly to the cause of the problem as the result of checks or measurements made. Refer to the description of the cause and carry out the repair procedures described on the right-hand side. The inspection methods/measurements are described in one step. YES should be chosen if the criteria or questions meet the situation; NO if they do not meet it. The necessary preparation work, operating method and the criteria are described under one step. This should be carefully read before starting the inspection and the measurements and the procedures should be followed, starting with step (1) since negligent preparation work or incorrect operating methods can cause damage to the machine.
Lep SC4604001-0EN
Table showing wire colours Symbol
Colour
Symbol
Colour
B
Black
R
Red
W
White
Y
Yellow
Br
Brown
Lg
Light green
P
Pink
Sb
Sky blue
V
Violet
L
Blue
G
Green
Gr
Grey
O
Orange
BR indicates a wire of colour B striped with R. Example: BR indicates a black wire with red stripes IMPORTANT : Before removing or installing a connector, always turn the key switch OFF.
Issued 03-07
Copyright © 4001-85
Procedures 1
This is how one has to proceed to detect defects when the message is still displayed after all necessary measures have been taken to correct the error. Message displayed
Description of the problem
Fuel
2
Problem No.
The message is still displayed even after refilling the fuel tank.
1
Low coolant
The message is still displayed even after refilling with coolant solution.
2
Low oil press.
The message is still displayed even after adjusting the engine oil pressure
3
Overheating
The message is still displayed even when the hydraulic oil temperature is 84°C (183° F) or less and the engine coolant temperature is 92°C (197° F) or less.
4
Alternator
The message is still displayed.
5
Elect. problem
The message is still displayed.
6
This is how one has to proceed if the problem is not indicated by a message but machine operation is not correct. A. Engine Description of the problem YES
The engine does not start.
«ELEC. PROBLEM» is shown on the monitor.
NO
3
Problem No.
6 7
Problem without message. Description of the problem Impossible to change travel speed
Lep SC4604001-0EN
Problem No. 8
Issued 03-07
Copyright © 4001-86
Fuel Description of problem No. 1 - The message is still displayed even after refilling the fuel tank.
R5 A1
CONTROLLER
CN1
CN23 14
GL413
FUEL SENSOR
CNB3 9
GL413 BG660
KEY SWITCH OFF 700.1.04.06.11E
A1 Computer/Controller
R5 Fuel sensor Troubleshooting
Cause
Action
Key switch ON Measure the fuel sensor resistance (R5) using maintenance support CHK4. (Refer to the table below for the resistance).
Replace the Computer/concomputer/ troller (A1) controller defective (A1)
YES
Key switch OFF Disconnect the fuel sensor connector (R5) to measure the resistance NO on the connector at the fuel sensor end. (Refer to the table below for the resistance).
NO
YES
Disconnect the CN23 connector to measure the resistance between NO GL female and the GND earth. (Refer to the table below for the resistance).
YES
Disconnect connector CN1 to measure the resistance between GL female and GND earth. (Refer to the table below for the resistance).
NO
Fuel sensor (R5) defective
Replace or check the fuel sensor (R5)
Bad connection on fuel sensor (R5)
Clean the connection terminal
Bad connection on CN23
Clean CN23 connection terminal
Replace the computer/ Defective comcontroller puter (A1) or (A1) or clean incorrect CN1 the CN1 conconnection nection terminal
YES
Note: All the bar-graph indicators are off when the circuit is open
Resistance between GL and BG Monitor
1. Refill the tank
2
3
4
5
6
7
8
Resistance (OHM)
70-80
61-75
46-61
37-46
30-37
24-30
18-24
10-18
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-87
Add coolant solution Description of problem No. 2 - The message is still displayed even after adding coolant solution.
CNB8
RESERVOIR 2 LEVEL SWITCH
GrG438
S56
BG642
CN4 CONTROLLER
CNB8
CN23 57
GrG437
6
RESERVOIR 1 LEVEL SWITCH
GrG437
S55
BG641
A1
700.1.04.06.11F2
A1 Computer/Controller S55 Reservoir tank low switch
S56 Reservoir tank low switch
Troubleshooting
Cause
Action
Key switch ON Disconnect the minimum coolant solution level switch connector (S55) to see if the message disappears
Defective minimum coolant solution level switch (S55)
YES
Short-circuit on wire GrG between the minRepair wire imum coolant GrG solution level switch (S55) and CN23
YES NO
Disconnect connector CN23 to see if the message disappears
NO
Disconnect connector CN4 to see if the message disappears
NO
Lep SC4604001-0EN
Replace the minimum coolant solution level switch (S55)
YES
Short-circuit on wire GrG between CN23 and CN4
Repair wire GrG
Defective computer/controller (A1)
Replace the computer/controller (A1)
Issued 03-07
Copyright © 4001-88
Low engine oil pressure Description of problem No. 3 - The message is still displayed even when the engine oil level is satisfactory.
A2
ENGINE CONTROLLER
OIL PRESSURE SENSOR
CNA2
CNA0 80
RY478
9
67
YB488
10
79
BY498
11
B21
700.1.04.06.11G
A2 Engine controller
B21 Engine oil pressure switch Troubleshooting
Cause
Action
Oil pressure switch (B21) defective
Replace the engine oil pressure switch (B21)
Short-circuit on wire between CNAO and CNA2
Repair wire
Defective engine controller (A2)
Replace engine controller (A2)
Check the following points during the 12 seconds following starting the engine
Disconnect the engine oil pres- YES sure switch connector (B21) to see if the message disappears
NO
Disconnect connector CNAO to see if the message disappears
NO
Lep SC4604001-0EN
YES
Issued 03-07
Copyright © 4001-89
Overheating Description of problem No. 4 - The message is still displayed even when the actual temperature is lower than the following: Hydraulic oil temperature 98°C (208°F), engine coolant temperature 105°C (221°F). Prior check: 1
Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs. ENGINE CONTROLLER CNA1 84
A2 CNA0 79
THERMO-SENSOR (COOLANT)
CNA2 CONTROLLER
A1
WR484
7
BY498
11
CN1 CN23
CND3
6
10
OL415
13
11
BO425
B1 THERMO-SENSOR (OIL)
B2
700.1.04.06.11H
A1 Computer/controller A2 Engine controller
Lep SC4604001-0EN
B1 Coolant temperature sensor B2 Hydraulic oil temperature sensor
Issued 03-07
Copyright © 4001-90 Troubleshooting 1
Cause
Action
Defective coolant temperature sensor (B1)
Replace the coolant temperature sensor (B1)
Bad connection on the coolant temperature sensor connector (B1)
Clean the coolant temperature sensor connecting terminal (B1)
Bad connections on CNAO, CNA1 or defective controller
Replace controller or clean CNAO, CNA1 connector terminal
The 8 bars on the coolant temperature bar-graph are displayed.
Key switch ON The temperature of the coolant temperature sensor (B1) is abnormal compared to maintenance assistance CHK1 YES (comparison between the actual temperature and the indicated temperature). See coolant temperature in CHK1 WT. Measure the actual temperature Check problem code E0015 for the coolant temperature sensor (B1) with the maintenance diagnostic (DIAG 1)
YES Disconnect connector CNA2 on the coolant temperature sensor (B1) to measure the resistance
YES
NO
Disconnect the connectors CNA1 and CNAO NO to measure the resistance between the male terminals. (Refer to the table below for the resistance).
YES
Note: In the event of a short-circuit, the bar-graph goes off completely.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-91
Overheating (continued) Troubleshooting 2
Cause
Action
The hydraulic temperature bar-graph displays 8 bars.
Key switch ON The hydraulic oil temperature sensor (B2) temperature is abnormal compared to mainYES tenance assistance CHK1 (comparison between the actual temperature and that indicated). See hydraulic oil temperature in CHK1 OT. Measure the actual temperature See problem code M0020 for the oil temperature sensor (B2) using maintenance diagnostic (DIAG 4)
YES Disconnect connector CND3 on the hydraulic oil temperature sensor NO (B2) to measure the resistance. (Refer to the table below for the resistance).
YES
Disconnect the CN23 connector to measure the resistance between the male terminals OL and BO. (Refer to the table below for the resistance).
YES
NO
Disconnect connector CN1 to measure the resistance between the female terminals OL and BO. (Refer to the table below for the resistance).
YES
NO
Defective hydraulic oil temperature sensor (B2)
Replace the hydraulic oil temperature sensor (B2)
Bad connection on the hydraulic oil temperature sensor connector (B2)
Clean the hydraulic oil temperature sensor connecting terminal (B2)
Bad connections on CN23
Clean the connecting terminal on CN23
Defective computer/ controller (A1) or bad connection on CN1
Replace the computer/ controller (A1) or clean the connecting terminals on CN1
Note: In the event of a short-circuit, the bar-graph goes off completely.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-92
Coolant and hydraulic oil temperature sensor resistance NOTE: The resistance varies with temperature. Coolant or hydraulic oil temperature
Coolant temperature sensor (B1)
Hydraulic oil temperature sensor (B2)
20°C (68°F)
2.50 kΩ
2.45 kΩ
30°C (86°F)
1.73 kΩ
1.66 kΩ
40°C (104°F)
1.20 kΩ
1.15 kΩ
50°C (122°F)
0.84 kΩ
0.81 kΩ
60°C (140°F)
0.61 kΩ
0.58 kΩ
70°C (158°F)
0.45 kΩ
0.43 kΩ
80°C (176°F)
0.31 kΩ
0.32 kΩ
Defective battery charge circuit Description of problem No. 5 - The message is still displayed.
CN13
S1 19
P5
KEY SWITCH
K7
G2 ALTERNATOR
LgR540
BATTERY RELAY HOUR METER
CNC9
CN22 2
A1
LgR540
7
LgR542
ENGINE CONTROLLER
B R
G020
SG
L
CN26
CN1 CONTROLLER
E
LgR540
1
BrR544
2
BrW545
4
A2
BrR030
M1 BrR543
STARTER
700.1.04.06.11J2
A1 A2 G2 K7
Computer/controller Engine controller Alternator Relay battery
Lep SC4604001-0EN
M1 Starter motor P5 Hourmeter S1 Key switch
Issued 03-07
Copyright © 4001-93 Troubleshooting NO The hour meter (P5) does not work YES
Cause
Disconnect connector CN1 to measure the voltage between the female terminal on wire WR and Ground. 10V or above.
NO
Action
Break in wire between CN1 and CN22
Repair wire
Bad connection on CN1 or defective controller
Clean CN1 connector terminal or replace controller
Defective alternator (G2)
Replace the alternator (G2)
Break in wire between CN22 and alternator or bad connection on alternator connector terminal of alternator
Repair wire between CN22 and alternator or clean the connector
YES
Disconnect the connector CNC9 on alternator R terminal to measure the voltage between alternator NO side and ground. 10 V or above. YES Disconnect connector CN22 to measure the voltage between the male terminal on wire LgR and ground. 10 V or above
NO
YES
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-94
Electrical system troubleshooting Description of problem No. 6 - The message is still displayed TRAVEL ALARM
K32
K5
HYDRAULIC FAN RELAY
CN.5
CONTROLLER
VR YR
5 1 2 3 4 1
8
24VB
REFUEL PUMP FREE SWING/BEACON WARNING BUZZER ENGINE STOP HYD. FAN REVERSE SWING BRAKE 2 SPEED TRAVEL CUSHION SWING SHUT-OFF SPARE 1 (PNP) SPARE 2 (PNP)
1 2
GW B
1 2
GW B
1 2
R Y
HYDRAULIC MOTOR (FAN) SOLENOID
Y31
FREE SWING SOLENOID
Y18
YW
CN22
RW PW
2 STAGE RELIFE
1.25RW 1.25B
H2
BEACON GrR B
VR CN.19
1 2
LR PW B GrR
YR RW B
LIMIT SWITCH (GATE)
2 1
BEACON RELAY
5 1 2 3 GR 4
S51
A1
W 0.85B
GR OW VW W
OW GW W WR RW VW LW LgW OR BrW WL WV
17 18 19 21 22 27 28 29 30 31 32 20 23
LW LgW OR BrW GW YW
SOLENOID VALVE 0.85GR OW 0.85VW W
1 2
0.85VW 0.85B
1 2
LEVER LOCK
Y2
SWING BRAKE
Y3
(PINK TAPE)
0.85LW 0.85LgW
1 3 6 4 5 2
0.85GR 0.85B
(BLUE TAPE)
0.85LW 0.85B
0.85BrW GW 0.85YW
1 2
2 SPEED TRAVEL
Y4
2 STAGE RELIEF
Y5
(RED TAPE)
0.85YW 0.85B
1 2 (YELLOW TAPE)
CN24
0.85LgW 0.85B
WR
CN.23
1 2
SOFT/HARD
Y6
(LIGHT GREEN TAPE)
16
CN.6
1 2
6 8 9 7
CONNECTOR (OPTION)
0.85BrW 0.85B
1 2
SWING SHUT-OFF
Y1
WR
(GREEN TAPE)
IS-ENGINE STOP SWITCH
47
CN.A0
A2 OPTION (REFUEL PUMP) REFUEL PUMP RELAY
ENGINE CONTROLLER (ECM)
PUMP STOP RELAY
S61
K31
AUTO / MANUAL SELECT SWITCH
K30 4 1 2 5 3
4 1 2 5 3
2GrR VR B 2LR
L OW B 0.85BrR VR
VR GW L
1 2 3
AUTO STOP ALARM
B82
0.85BrR 0.85B
M14 OW
1 3 2
2GrR OW 2B
2LR 2B
1 2
2R 2B
REFUEL PUMP
M
700.1.04.06.11KA
A1 Computer
A2 B82 H2 K5 K30 K31 K32 M14 S51
Engine controller Refuel pump stop alarm Travel alarm (North America) Relay-rotary light Refuel pump relay Refuel pump stop relay Relay, hydraulic fan Fuel feed pump motor Hydraulic function cancellation lever switch
Lep SC4604001-0EN
S61 Y1 Y2 Y3 Y4 Y5 Y6 Y18 Y31
Refuel pump switch Swing pilot shut-off solenoid valve (green band) Pilot pressure solenoid valve (blue band) Swing brake solenoid valve (pink band) 2 stage travel solenoid valve (red band) Power-up solenoid valve Cushion control solenoid valve (light green band) Free swing solenoid valve (North America) Cooling hydraulic motor solenoid valve
Issued 03-07
Copyright © 4001-95 Troubleshooting
Cause
Action
Troubleshooting using the diagnostic system Key switch ON Failure code displayed in DIAG 1 YES
Refer to the engine troubleshooting manual
NO Find troubled location by DIAG4 YES
M0020 appears
To CHK2
With automatic detection for short-circuit YES The failure code disappears after disconnecting the solenoid valve connector
YES
Defective (Yn) solenoid valve
Replace the solenoid valve (Yn)
Short-circuit on wire
Repair the wiring
Defective controller
Replace controller
NO The failure code disappears when either one of connectors CN21, CN22, CN23 in short-circuit line is disconnected
YES
NO The failure code disappears after disconnecting connector CN6 YES NO
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-96
ELECTRICAL INSPECTION OF COMPONENTS Details of service connector kit (380050017)
0.85 BW
0.85 WY
02A
0.85 WL
01A
0.85BW
50
01A
50 50
50
BrG BrG
200
50
03A
0.85WY
100
BrG 50
100 101
02A
150
100
0.85 WY
0.85 BW
01B
0.85 WL
02B 03A
03B
0.85WL
BrB
150
100
700.1.04.02.14AH
700.1.04.02.14AA
8. For pressure sensor (3P)
1. For solenoid valve and fuel sensor
0.85YL
200
50
01A 02A 03A
50
BrB
50
102 103
100
0.85 0.85 0.85 YL BY Y
150
50
BrG
50
BrB
102
01A
50
0.85BY 02A
BrG
150 103
03B 02B 01B 03A
0.85 0.85 0.85 BY YL Y
0.85Y
700.1.04.02.14AB
2. For electromagnetic proportional valve of hydraulic pump
700.1.04.02.14AI
9. For atmospheric pressure sensor
BrG BrG
BrB
104 105
0.85BO 01A
104 50
100
150
50
BrB
150
0.85BO
300
50
01A 02A
50
0.85OL
105 02A
700.1.04.02.14AC
3. For electromagnetic proportional valve of hydraulic pump
0.85OL
700.1.04.02.14AJ
10. For intake air temperature sensor
L L
106 107
1.25YG
106
BY 50
100
01A
150 50
BY
150
1.25 1.25 YG BY
01A 02A
1.25 1.25 BY Y
02A 01B
600
50
50 50
107 700.1.04.02.14AD
4. For pressure switch
01B 1.25Y
700.1.04.02.14AK
BY BY
108
L
108 109
50
100
150
11. For electromagnetic proportional valve of controlling fan speed (2P)
L
150
1.25RW
109
01A 50
700.1.04.02.14AE
5. For the harness side of pressure switch
50
01A 02A 1.25RW
800 50
1.25B
C C
C
814 850
02A
814 50
100
1.25B
150
700.1.04.02.14AL
C
150
12. For fan reversing solenoid valve (2P)
450 3B
700.1.04.02.14AF 01A
6. For receiver dryer (2P)
6 50
0.85BP
02A 01A
0.85BP 50
3B
01A
150
3LR
02A
50
02A 0.85PL
700.1.04.02.14AG
Lep SC4604001-0EN
6 02A
50
7. For oil temperature sensor
200 50
01A 50
0.85PL
50
3LR
700.1.04.02.14AM
13. For glow (1P)
Issued 03-07
Copyright © 4001-97
700.1.04.02.14AN
14. For fuel pump (6P) 700.1.04.02.14AP
16. For injector (12P)
700.1.04.02.14AO
15. EGR (8P) 700.1.04.02.14AQ
17. For sensor (20P)
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-98
Details of service connector kit (380350031) for breaker from engine controller (ECM) to main harness assembly
Engine controller C-2
Engine controller C-1
700.1.04.02.21P
1. For ECM-terminal
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-99
Engine controller (ECM)
700.1.04.02.21Q
2. For Main-terminal 1.250 001
50
150
50
1.250 001
50
1.250 002
700.1.04.02.21R
3. For Joint-terminal
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-100
Main pump proportional solenoid
6 solenoid valve bank 1. Disconnect connector (A) from one of the solenoids on the 6 solenoid valve bank (52)
1 Y5
Y1
Y4
Y7
Y2 Y6
700.1.04.02.21UA
1. Disconnect connector (1) from the main pump hydraulic solenoid (Y7).
Y3 52
5 A
2
3 CD00F023
4
Marking CS00E534
2. Connect the appropriate service connector (2P) (4) between the connector at the pump end (2) and the connector at the main harness end (3) and install the voltmeter (5). NOTE: The + terminal of the voltmeter should be connected to wire BrB (brown/black) on the service connector coming from the main harness and the - terminal to wire BrB (brown/black) on the service connector coming from the hydraulic pump. 3. When the connections have been made, start the engine and check the current on the voltmeter (5) in each work mode, at maximum speed.
Function
Y1
Swing pilot shut-off solenoid valve (green band)
Y2
Pilot pressure solenoid valve (blue band)
Y3
Swing brake solenoid valve (pink band)
Y4
2 stage travel solenoid valve (red band)
Y5
Power-up solenoid valve (yellow band)
Y6
Not used (light green band)
2
Yn 3
Current in mA H
S
Maxi
Min
Maxi
Min
490
240
405
240
L
<50
Auto S
L
490
490
1 CS99A843
2. Connect the appropriate service connector (2P)(3) to the connector on the disconnected solenoid (1) only (Yn) and install the voltmeter (2). 3. When the connection has been made, the solenoid resistance reading on the voltmeter (2) should be 45 Ω at 20°C (68° F). NOTE: The resistance value varies with temperature.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-101
Hydraulic oil temperature sensor
B2
3. When the connection has been made, place the temperature sensor (B2) in the beaker (5) containing water. Place the beaker (5) on the tripod (7). Using the spirit lamp (8) gradually increase the water temperature in the beaker (5). Using the voltmeter (9), check the resistance value in function of the temperature read on the thermometer (4) (see table below). Oil Temperature
Oil temperature sensor
20°C (68°F)
2.45 kΩ
30°C (86°F)
1.66 kΩ
40°C (104°F)
1.15 kΩ
50°C (122°F)
0.81 kΩ
60°C (140°F)
0.58 kΩ
70°C (158°F)
0.43 kΩ
80°C (176°F)
0.32 kΩ
Pressure sensor 700.1.04.02.21AB
B2 Hydraulic oil temperature sensor
B42
1. Remove the oil temperature sensor (B2) from the machine.
B44
3 4 5
9 6
700.104.02.21AD1
7 8 CS99A851
3 4 5 6 7 8 9
Service connector (2P) Thermometer Beaker Temperature sensor (B2) Tripod Spirit lamp Voltmeter
B43
2. Connect the appropriate service connector (2P) (3) to the temperature sensor (B2) connector (1) or (2) and install the voltmeter (9). 700.1.04.02.21AB1
B42 Pressure sensor P1 B43 Pressure sensor (nega-cont.) (N) B44 Pressure sensor P2 1. Disconnect the connector from the main hydraulic pump pressure sensor.
Lep SC4604001-0EN
Issued 03-07
Copyright © 4001-102
(psi) (MPa)
5
(7252) (725) (580)
B42 4
B43
1
2
3
(435)
(290)
B44
(145)
Pressure
6
Voltage (V) 700.1.04.02.21.AG
CS00E541
2. Connect the appropriate service connector (3P)(4) between sensor (B42), (B43) or (B44) and the corresponding connector (1), (2) or (3) of the main harness (5) and install the voltmeter (6). NOTE: The + terminal on the voltmeter should be connected to wire YL (yellow/blue) on the service connector and the - terminal to the machine earth. 3. When the connection has been made, start the engine and check the voltage read on the voltmeter (6) in accordance with the pressures indicated in the table below. Pump pressure sensor (B42) and (B44) Pressure (MPa)
Voltage (V)
50 (7252 psi)
4.5
43.7 (6338 psi)
4
37.5 (5439 psi)
3
25 (3626 psi)
2
17.5 (2538 psi)
1
0
0.5
Pressure sensor (nega-cont.) (B43) Pressure (MPa)
Voltage (V)
5 (725 psi)
4.5
4.37(634 psi)
4
3.75 (544 psi)
3
2.50 (362 psi)
2
1.25 (181 psi)
1
0
0.5
NOTE: Formula for converting pressure: 1MPa = 1.019 x 10 kgf/cm2
Lep SC4604001-0EN
Issued 03-07
Copyright ©
4003
Section 4003 MAIN ELECTRONIC CONTROL BOX ENGINE ELECTRONIC CONTROL BOX
CNH
Lep SM4604003-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 4003-2
TABLE OF CONTENTS MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX ................................................. 3 Removal ...................................................................................................................................................................... 3 Main electronic control box ......................................................................................................................................... 3 Engine electronic control box ...................................................................................................................................... 4 Installation ................................................................................................................................................................... 4
Lep SM4604003-0EN
Issued 09-07
Copyright © 4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX Removal
STEP 4
STEP 1
B A
C
CD00F011
JS00001A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Shut down the engine and position the starter switch on OFF.
Remove the panel (A) located behind the operator’s seat, taking care to disconnect the connector from the cigarette lighter (B) and the solar radiation detector (C).
Main electronic control box STEP 5
STEP 3
B
A CD00F047
Disconnect the connectors CN1 to CN6 from the main electronic control box (B). Disconnect the main earth cable (-) (1) from the battery.
STEP 6 Remove the 4 retaining screws (A) from the main electronic control box (B).
STEP 7 Remove the main electronic control box (B).
Lep SM4604003-0EN
Issued 09-07
Copyright © 4003-4
Engine electronic control box STEP 5
CNA1 K10
K11
K32
D
K6
K5 CNA0
C
Identify and remove the relay-rotary light (K5), the relay-air conditioner condenser fan (K6), the relay, hydraulic fan (K32), the relay-working light (cab) (K11) and the relay-working light (upperstructure /attachment) (K10).
STEP 6 Disconnect the connectors CNA0 and CNA1 from the engine electronic control box (C).
STEP 7 Remove the retaining screws (D) from the engine electronic control box (C).
STEP 8 Remove the engine electronic control box (C).
Installation To install, proceed in the reverse order from that of removal. NOTE: To reprogram the main and engine electronic control boxes, see Section 4001.
Lep SM4604003-0EN
Issued 09-07
5001
Copyright ©
Section 5001 REMOVAL AND INSTALLATION OF THE TRACKS SET
CNH
Lep SM160B5001-0EN
Copyright © 2007 CNH France S.A. Printed in France May 2007
Copyright © 5001-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS..................................................................................................................................... 2 SPECIAL TOOLS ........................................................................................................................................................... 3 TRACKS SET................................................................................................................................................................. 4 Description ................................................................................................................................................................. 4 Removal ..................................................................................................................................................................... 5 Installation .................................................................................................................................................................. 8 Track tension adjustment ......................................................................................................................................... 10 Checking pin and bushing wear ............................................................................................................................... 12
!
WARNING: This symbol is used in this manual to indicate important safety messages. Every time you see this symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.
SPECIFICATIONS See Section 1002
SPECIAL TORQUE SETTINGS See Section 1002
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-3
SPECIAL TOOLS
926407
1. Track removal hydraulic press CAS 10044 2. Loctite 262 3. Hammer 4. Lifting jib 5. Impact wrench 6. Torque spanner 7. Supports 10 T 8. Roller pump 9. Protractor attachment CAS 2162
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-4
TRACKS SET Description Lower mechanism
6
12
5 7 8 7 4 14 9 11
13
14 3 10
1
2
CI00E511
1 2 3 4 5 6 7
TRACK PAD SCREW NUT END OF CHAIN PIN HALF-LINK END OF CHAIN HALF-LINK END OF CHAIN PIN SHIM
Lep SM160B5001-0EN
8 9 10 11 12 13 14
END OF CHAIN PIN SPACER RETAINER PIN RH STANDARD TRACK PIN HALF-LINK LH STANDARD TRACK PIN HALF-LINK STANDARD TRACK PIN STANDARD TRACK PIN SPACER UNION
Issued 05-07
Copyright © 5001-5
Removal STEP 1 Park the machine on hard, flat ground. Rotate the upperstructure of the machine so that the cab is over the track to be removed.
2
STEP 2
JD00272A
Operate the machine until the main axle is close to the centre of the sprocket. Operate machine to lower track to be removed to ground. Rotate the upper structure of the machine so that the cab is facing the front. Shut down the engine.
STEP 4 JD00270A
Lower the bucket or the tool to lift the track a few centimetres off the ground. NOTE: If the machine does not have a bucket or tool installed, install wood blocks under the dipper and lower the dipper onto the wood blocks. Then, lower the dipper to raise the machine.
STEP 3
JD00273A
Do not remove the non-return check valve. The grease in the track adjustment cylinder is under high pressure. Slacken the track by gradually loosening the non-return check valve by about two turns. The grease will escape from a port on the check valve thread.
1
JD00271A
The main axle (1) can be identified by flat surfaces on one end and the pin (2) that fastens it at the other end.
Lep SM160B5001-0EN
!
WARNING: Grease is under heavy spring pressure. Disassembly without releasing pressure may result in serious injury or death. Do not disassemble the track compensating system before completely releasing the grease pressure. Release grease pressure by loosening check valve. Do not remove the non-return check valve or retaining bracket.
Issued 05-07
Copyright © 5001-6
STEP 5
STEP 7
1
JD00274A
JD00277A
Remove the four screws (1) and the track pad nuts on top of the end of chain axle. Remove the track pad.
Remove the four screws and the nuts from the track pad under the end of chain axle. Remove the track pad.
STEP 6
STEP 8
1
JD00275A
B504423M
Install a portable hydraulic press CAS 10044 on the end of chain axle. Using the portable hydraulic press, force the end of chain axle out.
STEP 9 Remove the portable hydraulic press.
JD00276A
Straighten up one end of the pin (1) and remove the pin from the end of chain axle.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-7
STEP 10
STEP 12
1
JD00278A
Using a crowbar, separate the chain links. Remove the two spacers (1) from the end of chain axle.
STEP 11
JS00280A
Sling the lower end of the track. Start the engine. Operate the machine backwards and move the dipper out at the same time. When the track is free from the sprocket, stop reversing the machine. Continue operating the dipper out until the track is pulled from beneath the machine. Stop the engine, move the track to be replaced away from the machine.
JD00279A
Start the engine. Using the attachment, lift the upperstructure on the side of the track to be removed. Install supports under the machine to hold the machine in place and lower the machine onto the supports. Shut down the engine.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-8
Installation
STEP 4
STEP 1
CD00F057
JD00279A
Lift the undercarriage. Install supports under the machine to hold the machine in place.
Connect lifting equipment to the track. Lift the track on the idler wheel.
STEP 5
STEP 2
JS00283A
JD00281A
Place and align the new track under the lower roller.
STEP 3
Sling the track to the attachment. Start the engine, operate the machine forward and move the dipper out at the same time to pull the track on the sprocket. Keep the track engaged on the sprocket teeth.
Lower the machine onto the track chain.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-9
STEP 6
STEP 9
1
B5573689M
JD00284A
Connect suitable pulling equipment to both ends of the track chain. Operate the pulling equipment to pull both ends of the track chain together.
Remove the portable hydraulic press. Install a new pin (1) in the end of chain axle. Bend the ends of the pins to brake the end of chain axle.
STEP 7
STEP 10 Install the two track pads, the screws and the nuts.
STEP 11
1
JD00278A
Install two spacers (1) in the two half links where the end of chain axle is assembled.
STEP 8
B5171389M
Tighten the track pad screws to a torque (see the specifications).
STEP 12 See "Track tension adjustment" in this section and adjust the track tension.
B5491989M
Install the end of chain axle with the portable hydraulic press CAS 10044.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-10
Track tension adjustment
STEP 4
Check the tension of the tracks as required. Adjust the tension for the type of surface the machine will be operating on. Tighten the track for operation on hard surfaces and loosen the track for operation on soft surfaces.
Do the following procedure to increase the track tension: 1. Clean the grease fitting of the track adjustment cylinder.
STEP 1 Park the machine on hard, flat ground. Rotate the upper structure of the machine so that the cab is over the track to be checked.
STEP 2
JD00273A
2. Check that the check valve is tight.
JD00270A
Lower the attachment to lift the machine until the track to be checked is lifted off the ground by a few centimetres.
STEP 3
JD00287A
3. Inject grease into the track tension cylinder until the required tension is obtained.
JD01074A
Measure the distance between the bottom surface of the track frame and the top surface of the track shoe. Compare the values with the specifications.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-11
STEP 5 Do the following procedure to decrease the track tension:
JD00273A
1. Do not remove the non-return check valve. Grease in the track tension cylinder is under high pressure. Release the track by gradually loosening the nonreturn check valve by about two turns, the grease escapes from a port in the check valve thread.
!
WARNING: Grease is under havy spring pressure. Disassembly without releasing pressure may result in serious injury or death. Do not disassemble the track compensating system before completely releasing the grease pressure. Release grease pressure by loosening check valve. Do not remove the non-return check valve or retaining bracket.
2. When the track tension is correct, tighten the check valve. 3. Clean the grease from the check valve.
Lep SM160B5001-0EN
Issued 05-07
Copyright © 5001-12
Checking pin and bushing wear The wear on the pins and bushings can be measured with a micrometer or an outside calliper.
STEP 1 1
2
STEP 2 Measure the inside diameter of the bushing. Compare the values with the specifications. Replace them if necessary.
STEP 3 Measure the outer diameter of the track pin. Compare the values with the specifications. Replace them if necessary.
JS00288A
1 2
OUTSIDE CALLIPER BUSHING
Measure the outer diameter of the bushing. Compare the values with the specifications. Replace them if necessary.
Lep SM160B5001-0EN
Issued 05-07
Copyright ©
5003
Section 5003 UPPER AND LOWER ROLLERS
CNH
Lep SM4605003-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 5003-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 3 SPECIAL TORQUE SETTINGS...................................................................................................................................... 3 SPECIAL TOOLS ............................................................................................................................................................ 3 LOWER ROLLER............................................................................................................................................................ 4 Description ................................................................................................................................................................. 4 Removal ..................................................................................................................................................................... 5 Reconditioning ........................................................................................................................................................... 6 Disassembly ............................................................................................................................................................... 6 Inspection ................................................................................................................................................................... 7 Assembly ................................................................................................................................................................... 7 Installation .................................................................................................................................................................. 9 UPPER ROLLER........................................................................................................................................................... 10 Description ............................................................................................................................................................... 10 Removal ................................................................................................................................................................... 11 Reconditioning ......................................................................................................................................................... 12 Disassembly ............................................................................................................................................................. 12 Inspection ................................................................................................................................................................. 14 Assembly ................................................................................................................................................................. 15 Installation ................................................................................................................................................................ 17 CHECKING FOR LEAKS .............................................................................................................................................. 18
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-3
SPECIFICATIONS See Section 1002.
SPECIAL TORQUE SETTINGS See Section 1002.
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 for the leak checks shown below.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-4
LOWER ROLLER Description A B 7
C
F 3
E
D G
2
1
6
8
5
4 KTA1106Z-C02
1 2 3 4
LOWER ROLLER DRAIN PLUG WIRE CLIPS END BEARING
5 6 7 8
FACE SEAL SHAFT O-RING BUSHING
A.......................................................................................................................................................... 406 mm (15.88 in) B........................................................................................................................................................... 318 mm (12.52 in) C............................................................................................................................................................. 223 mm (8.78 in) D......................................................................................................................................................... Ø 200 mm (7.87 in) E ............................................................................................................................................................... 36 mm (1.42 in) F ............................................................................................................................................................. 170 mm (6.69 in) G........................................................................................................................................................... Ø 85 mm (3.35 in)
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-5
Removal
STEP 5
STEP 1 Park the machine on hard, flat ground. Swing the upperstructure of the machine so that the cab is over the lower rollers to be removed.
STEP 2
1 JD01076A
At each end of the track, install wood blocks (1) under the track.
STEP 6
JD00273A
Do not remove the non-return check valve. The grease in the track adjustment cylinder is under high pressure. Slacken the track by slowly loosening the non-return check valve by about two turns, the grease will escape from a port in the check valve thread.
!
WARNING: Grease is under heavy spring pressure. Disassembly without releasing pressure may result in serious injury or death. Do not disassemble the track compensating system before completely releasing the grease pressure. Release grease pressure by loosening check valve. Do not remove the non-return check valve or the retaining bracket.
JD00299A
Install a wood block under the lower roller to support it. Remove the screws and the retaining washers and remove the lower roller.
STEP 3 Lower the attachment to lift the machine until a sufficient gap between the track frame and the track is obtained so that the lower roller can be removed.
STEP 4
1 JD01075A
Install supports (1) of suitable capacity under the machine.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-6
Reconditioning
STEP 3
When the roller is worn out or is leaking, it must be reconditioned or replaced by a new one. See Section 1002 for limits of wear.
4 5
Disassembly STEP 1 1
JS00303A
2
Remove the face seals (5) from the end bearings (4) with a screwdriver or similar tool. Be careful not to damage the seal bore in the end bearing. Discard the face seals.
STEP 4 000-6-04-0021B
Clean the lower roller (1) using a suitable solvent. Remove the two drain plugs (2) and drain the oil.
STEP 2 7
4
7 3
6
3 6
1 JS00304A
Remove and discard the O-rings (7) from the shaft (6). Remove the shaft (6) from the lower roller (1).
4
STEP 5 000-6-04-0021C
Remove the retainer rings (3) and the end caps (4) from the shaft (6). Discard the retainer rings.
1
5
5 JS00305A
Remove and discard the face seals (5) from the lower roller (1) or the shaft (6).
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-7
Assembly
STEP 6
STEP 1 8 1 8
8 1 8
JS00306A
NOTE: Carry out this step only if inspection reveals that the bushings (8) need to be replaced. Using a hammer and a brass drift, drive the bushings (8) out of the lower roller (1). Be careful not to damage the seal bore in the lower roller. Discard bushings.
JS00309A
If the bushings (8) were removed, install new bushings (8) in the lower roller (1) using a hydraulic press and an appropriate centring piece.
STEP 2
Inspection 5
STEP 1 Clean all components with solvent.
STEP 2 Inspect the bushing surfaces on the shaft (6) for scoring, pitting, and other damage. Measure the diameter of the shaft at four opposing points. Compare the values with the specifications, replace them if necessary.
STEP 3 Inspect bushings (8) for wear and damage. Measure the inner diameter and width of the bushing. Compare the values with the specifications, replace them if necessary.
5
1 JS00310A
Install an O-ring and a face seal metal bushing (5) in the seal bore on each side of the lower roller.
STEP 4 Inspect the bore in each end bearing and in the lower roller for damage that will result in leakage. Use new parts as required.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-8
STEP 3
STEP 5 3 1 3
7
4 6 1
4
7 JS00311A
Apply clean grease on the shaft surface (6) and install the shaft in the lower roller (1), lubricate and assemble the O-rings (7) on the shaft (6).
STEP 4 4
000-6-04-0021C
Install the end caps (4) on the shaft (6) and install new retainer rings (3). NOTE: Check the adjustment settings of the face seal covers as well as those of the retaining pitch holes, see page 4.
STEP 6 See the chapter on leak checks, carry out an inspection to ensure that the lower roller has been correctly installed.
5
STEP 7 3 3 JS00312A
A
000-6-04-00-21M
Install the wire clips (3) using a hammer.
5 4
JS00313A
Install the O-ring and remaining face seal metal bushings (5) in the seal bore of the end cap (4). Apply clean oil copiously to the face seals (A).
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-9
Installation
STEP 8
STEP 1 1 4 2
000-6-04-0021B
Fill the lower roller (1) with clean oil, see specifications. Install the drain plug (2) in the end cap (4).
JD00316A
Align the lower roller in position under the lower undercarriage.
STEP 2
JD00299A
Apply Loctite 262 to the screw threads. Assemble the hardened washers and the screws.
STEP 3 Tighten the retaining screws of the lower roller end bearings to torque (see Specifications). Remove the wood blocks.
STEP 4 At each end of the track, remove the wood blocks from beneath the track. Remove the two supports from beneath the machine.
STEP 5 Refer to "Track tension setting" in Section 5001.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-10
UPPER ROLLER Description
A 4
B
C
K 11
5
D
E
2 3
F J 6
7
9 10
8
1
G
H
300.6.03.01.08ABIS
1 2 3 4 5 6
UPPER ROLLER OIL DRAIN PLUG SCREW COVER SEAL THRUST PLATE
7 8 9 10 11
SHAFT FACE SEAL BUSHING BUSHING BRACKET
A............................................................................................................................................................. 186 mm (7.32 in) B............................................................................................................................................................. 103 mm (4.05 in) C............................................................................................................................................................ 11.5 mm (0.45 in) D......................................................................................................................................................... Ø 150 mm (5.90 in) E ........................................................................................................................................................... Ø 65 mm (2.55 in) F ............................................................................................................................................................. 147 mm (5.78 in) G............................................................................................................................................................... 50 mm (1.96 in) H............................................................................................................................................................. 152 mm (5.98 in) J ............................................................................................................................................................... 30 mm (1.18 in) K............................................................................................................................................................. 104 mm (4.09 in)
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-11
Removal
STEP 3
STEP 1
JD00317A
JS00163A
Park the machine on hard, flat ground. Lower the tool to the ground.
STEP 2
Install a hydraulic jack on the side frame. Using the jack, lift the track just enough to remove the upper roller.
STEP 4
JD00318A JD00273A
Do not remove the non-return check valve. The grease in the track adjustment cylinder is under high pressure. Slacken the track by slowly loosening the non-return check valve by about two turns, the grease will escape from a port in the check valve thread.
!
Place wooden shims between the track and the undercarriage.
STEP 5
WARNING: Grease is under heavy spring pressure. Disassembly without releasing pressure may result in serious injury or death. Do not disassemble the track compensating system before completely releasing the grease pressure. Release grease pressure by loosening check valve. Do not remove the non-return check valve or the retaining bracket. JD00319A
Unscrew the screws which fasten the upper roller to the undercarriage. Support and remove the upper roller.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-12
Reconditioning
STEP 3
When the upper roller is worn or is leaking, it must be reconditioned or a new upper roller installed. See Section 1002 for limits of wear.
Disassembly 3
STEP 1
6
1
7 1
2
CS02B507
Secure the upper roller in a vice. Remove the screws (3) holding the thrust plate (6). Remove the thrust plate (6).
STEP 4 1 CS02B505
Clean the upper roller (1) using a suitable solvent. Remove the drain plug (2) and drain the oil.
7
STEP 2
3 4
CS02B508
Pull the upper roller (1) from the shaft (7).
5
NOTE: Carry out Step 5 only if inspection reveals that the shaft (7) needs to be replaced.
1
STEP 5 CS02B506
Remove the screws (3) and the cover (4) from the upper roller (1). Remove and discard the O-ring (5) from the cover (4).
Lep SM4605003-0EN
Using a press, remove the shaft (7) from the bracket (11). Be careful not to damage the seal bore in the bracket.
Issued 09-07
Copyright © 5003-13
STEP 6
NOTE: Carry out Step 8 only if inspection reveals that the bushings (9) and (10) need to be replaced.
STEP 8 1
9 8 1 10
CS02B509
Remove and discard the face seal (8) on the upper roller (1) using a screwdriver or equivalent tool. Be careful not to damage the seal bore in the upper roller.
STEP 7 7
8
CS02B511
Using a hammer and a brass punch, drive the bushings (9) and (10) from the upper roller (1). Be careful not to damage the seal bore in the upper roller.
7
8
11
11
000.6.03.00.24H
Remove and scrap the face seal (8) from the bracket (11) using a screwdriver or other suitable tool. Be careful not to damage the seal bore in the bracket.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-14
Inspection STEP 1 Clean all components with solvent.
STEP 2 Inspect the bushing surfaces on the shaft (7) for scoring, pitting and other damage. Measure the diameter of the shaft at four opposing points. Compare the values with the specifications, replace if necessary.
STEP 3 Check for wear and damage to the bushings. Measure the inner diameter and width of the bushing. Compare the values with the specifications, replace if necessary.
STEP 4 Inspect the thrust plate for wear and damage. Measure the thickness of the thrust plate. Compare the values with the specifications, replace if necessary.
STEP 5 Inspect the bore in the bracket (11) and the upper roller (1) for damage that could result in leakage. Use new parts as required.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-15
Assembly
STEP 3
STEP 1 1
7
8
11
CS02B509
CS02B512
If the shaft (7) has been removed from the bracket (11), install the shaft in the bracket using a press. Be careful not to damage the seal bore in the bracket.
Install an O-ring and a face seal (8) metal bushing in the seal bore of the upper roller (1). Liberally apply clean oil on the edge of the face seal.
STEP 4
NOTE: The retaining ports of the thrust plate (6) should be perpendicular to the retaining plane of the bracket (11). NOTE: Respect the recess dimension of the shaft in the bracket, see page 10.
STEP 2
8
11
8 9
10 7 1
000.6.03.00.24K
Install the the face seal (8) in the bracket seal bore (11). Apply clean oil copiously to the face seal.
9 1
STEP 5
10
1
10 CS02B513
7
Install the bushings (9) and (10) in the upper roller (1). NOTE: The grooves of the bushings should be rotated by 90°.
CS02B508
Apply clean grease on the surface of the shaft (7) and install the shaft in the upper roller (1).
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-16
STEP 6
STEP 9 1
2 3 6 1 CS02B515
Apply grease on the inside of the thrust plate (6). Position the thrust plate on the shaft (7) and install the screws (3). Apply brake thread fluid to the screws and tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft) to (53.55 lbf-ft).
CS02B505
Fill the upper roller (1) with synthetic oil (see the specifications for quantity). Install the drain plug (2) in the cover (4). Tighten the plug to a torque of 24.5 Nm (18.07 lbf-ft).
STEP 7
3 4 5 1 CS02B506
Apply grease on the seal (5) and install in the groove of the cover (4). Install the cover on the upper roller (1) using screws (3). Apply brake thread fluid to the screws and tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft) to (53.55 lbf-ft).
STEP 8 Check for leaks to ensure that the upper roller has been correctly reassembled and check for any damage which could give rise to leaks at seals and other components.
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-17
Installation
STEP 3
STEP 1
JD00317A
JD00338A
Place the shims on the undercarriage, then install and support the upper roller.
Remove the wood blocks between the track pad and the undercarriage.
STEP 4 Operate the hydraulic jack to lower the track onto the upper roller. Remove the jack.
STEP 2
STEP 5 Refer to "Track tension setting" in Section 5001.
JD00319A
Apply Loctite 262 to the screw threads. Install two tempered washers and screws to fasten the upper roller bracket to the undercarriage. Tighten the screws to torque (see specifications).
Lep SM4605003-0EN
Issued 09-07
Copyright © 5003-18
CHECKING FOR LEAKS Use CAS 1450 and CAS 1682 for the leak checks shown below.
STEP 4 Connect the pressure gauge pipe to the quick coupler.
STEP 5 Make sure that the shut-off valve (1) is open.
1
STEP 6 Adjust the pressure regulator (2) until the pressure gauge shows 1.9 bar (0.2 MPa/29 PSI).
STEP 7 Turn the shaft of the unit under test four revolutions.
STEP 8 2
Adjust the regulator until the pressure gauge shows 1 bar. B407320M
STEP 1 Connect the shut-off valve (1) to the pressure regulator (2). Connect a union for the air supply hose to the shutoff valve.
STEP 9 Close the shut-off valve. Maintain the air pressure of Step 8 for 10 seconds. A reduction in air pressure during this period shows a defective component or incorrect assembling.
STEP 2 Install the adaptor and a quick coupler to the oil filler orifice. Use a seal washer with the adapter.
STEP 3 Turn the knob anti-clockwise to close the pressure regulator (2).
Lep SM4605003-0EN
Issued 09-07
Copyright ©
Section
5004
5004 SPROCKET
CNH
Lep SM160B5004-0EN
Copyright © 2007 CNH France S.A. Printed in France May 2007
Copyright © 5004-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS..................................................................................................................................... 2 SPROCKET.................................................................................................................................................................... 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 4
SPECIFICATIONS See Section 1002.
SPECIAL TORQUE SETTINGS See Section 1002.
Lep SM160B5004-0EN
Issued 05-07
Copyright © 5004-3
SPROCKET Removal
STEP 4
STEP 1 See “Removing and installing the tracks” (Section 5001) and removing the sprocket from the chain.
1
STEP 2
JD00292A
To facilitate reassembly, make alignment marks (1) on the sprocket and the reduction gear.
STEP 5
JD00290A
Move the machine so that the track is in the position shown.
STEP 3
1
JD00293A
Remove the screws (1) and the hardened washers that attach the sprocket to the reduction gear.
STEP 6
JD00291A
Rotate the upperstructure so that the cab is over the side of the machine where the sprocket to be removed is located. Using the attachment, lift the side of the machine until the teeth of the sprocket are free from the chain. NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
JD00294A
Drive the sprocket from the reduction gear housing using a soft hammer. Remove the sprocket from the machine.
Lep SM160B5004-0EN
Issued 05-07
Copyright © 5004-4
Installation
STEP 3
NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
STEP 1
1
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble the hardened washers and the screws.
STEP 4 JD00292A
Install the sprocket on the drive reduction gear taking care to align the reference marks (1).
1
STEP 2 3
4
2 JS00296A
Tighten the four screws to torque in the order shown, see "specifications". Then progressively tighten the remaining screws to the same torque setting. JD00295A
If necessary, use a soft hammer to seat the sprocket properly on the flange of the reduction gear.
Lep SM160B5004-0EN
STEP 5 To install the tracks, see “Removing and installing the tracks”.
Issued 05-07
Copyright ©
Section 5005
5005
IDLER WHEEL AND TENSION SHOCK ABSORBER
CNH
Lep SM4605005-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 5005-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 3 SPECIAL TORQUE SETTINGS...................................................................................................................................... 3 SPECIAL TOOLS ............................................................................................................................................................ 3 REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER ....................... 4 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 6 DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL .......................................................................................... 8 Description ................................................................................................................................................................. 8 Reconditioning ........................................................................................................................................................... 8 Disassembly ............................................................................................................................................................... 9 Inspection ................................................................................................................................................................. 10 Assembly ................................................................................................................................................................. 11 Leakage test ............................................................................................................................................................ 13 DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER .............................................................. 14 Description ............................................................................................................................................................... 14 Disassembly ............................................................................................................................................................. 15 Assembly ................................................................................................................................................................. 15 TRACK TENSION CYLINDER ...................................................................................................................................... 16 Description ............................................................................................................................................................... 16 Removal ................................................................................................................................................................... 17 Disassembly ............................................................................................................................................................. 17 Inspection ................................................................................................................................................................. 18 Assembly ................................................................................................................................................................. 18 Installation ................................................................................................................................................................ 19
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-3
SPECIFICATIONS Idler wheel............................................................................................................................................. See Section 1002
SPECIAL TORQUE SETTINGS Shock absorber spring yoke screw* ......................................................... 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft) Tension cylinder screw* ............................................................................ 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft) Tension cylinder non-return valve .......................................................................................................59 Nm (43.52 lbf-ft) Mounting length of spring..................................................................................................................... 740 mm (29.13 in) * Apply Loctite 262 to the threads
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 to check for leaks as below
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-4
REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER Removal
STEP 4
NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
STEP 1 Disconnect the chain. See "Removal and installation of the tracks", Section 5001.
STEP 2
JD00341A
Using a crowbar, move the idler wheel and the shock absorber spring assembly out of the housing in the undercarriage.
STEP 5
JD00339A
Start the engine. Move the machine until the track chain is disengaged from the idler wheel. Shut down the engine.
STEP 3
JD00342A
Move the idler wheel and the shock absorber spring assembly out of the housing in the undercarriage, using a crowbar, until the nylon sling can be attached to the shock absorber spring assembly.
JD00340A
Attach the nylon sling from the lifting equipment to the idler wheel.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-5
STEP 6
STEP 8
JD01077A
Raise and remove the idler wheel and the shock absorber spring assembly.
STEP 7
JD00345A
Connect the lifting equipment to the idler wheel. Remove the four screws and hardened washers which attach the idler wheel to the yoke. Remove the idler wheel from the yoke.
JD01078A
Place the idler wheel and the shock absorber spring on wooden blocks. Remove the lifting equipment from the shock absorber spring assembly.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-6
Installation
STEP 3
NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
STEP 1
JD00342A
JD00362A
Attach a suitable lifting device to the idler wheel and bring it into position on the yoke. Apply Loctite 262 to the threads of the idler wheel retaining screws. Install four hardened washers and screws to fasten the idler wheel to the tension shock absorber yoke. Tighten the screws to torque (see specifications).
Raise the idler wheel and the tension shock absorber and install them in the undercarriage housing. Push the idler wheel and the tension shock absorber into the undercarriage. Remove the lifting device from the idler wheel and from the back of the tension shock absorber.
STEP 4
STEP 2
JD00363A
Insert the lifting device nylon sling into the central orifice of the tension shock absorber yoke.
JD01078A
Attach the lifting device nylon sling to the assembly.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-7
STEP 5
JD00365A
Raise the assembly and slide it into the undercarriage, with the help of a crowbar. Remove the lifting equipment.
STEP 6 See "Removal and installation of (Section 5001), for installing the track.
Lep SM4605005-0EN
the
tracks"
Issued 09-07
Copyright © 5005-8
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL Description
2
8
7
5
6
3
4
1
B A
CS02B516
1 2 3 4
PLUG IDLER WHEEL RETAINER PIN SLIDE
5 6 7 8
SEAL SHAFT FACE SEAL BUSHING
A........................................................................................................................................................... 386 mm (15.19 in) B........................................................................................................................................................... 278 mm (10.94 in)
Reconditioning If the idler wheel is worn to the indicated limits or if it shows traces of leaks, it must be reconditioned or changed. See Section 1002 for limits of wear.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-9
Disassembly
STEP 3
STEP 1 2 5 1 2
6 4
4
CS02B519
CS02B517
Clean the idler wheel (2) with a suitable solvent. Install the idler wheel (2) on supports, with the drain plug (1) at the bottom. Remove the drain plug (1) from the slide (4) and drain the oil.
Remove and scrap the O-ring (5) from the shaft (6). Remove the shaft (6) with the slide (4) from the idler wheel (2).
STEP 4
STEP 2 3 4
6 3
6 5
4
4
2
CS02B520
CS02B518
Remove the retainer pin (3) at one end. Remove the slide (4) from the shaft (6).
Remove the retainer pin (3) from the slide (4). Remove the slide (4) from the shaft (6), remove and scrap the Oring (5) from the shaft (6).
STEP 5 7 4 7
4 CS02B521
Remove and scrap the face seal (7) from the slide (4) using a screwdriver or equivalent tool. Be careful not to damage the seal bore in the slide.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-10
Inspection
STEP 6 2
7
7
STEP 1
2
Clean all the components with cleaning solvent. Also clean the cavity in the idler wheel. Dry all the components with compressed air at low pressure and apply clean oil to all the components.
STEP 2 Inspect the bushing surfaces on the shaft for scoring, pitting and other damage. Measure the diameter of the shaft at four opposing points. Compare the values with the specifications. Change them if necessary.
7 7 CS02B522
Remove and scrap the face seal (7) from the idler wheel (2) using a screwdriver or suitable tool. Make sure you do not damage the idler wheel seal bore.
STEP 7 8
STEP 3 Check for wear and damage to the bushings. Measure the inner diameter and width of the bushing. Compare the values with the specifications. Change them if necessary.
STEP 4
8
Check for damage which could give rise to leaks at the slide seal and idler wheel bores. Replace the components with new components as required. Measure the depth of the slide seal bores. Compare the values with the specifications. Change them if necessary.
2 CS02B523
NOTE: Carry out this step only if the inspection in Step 3 reveals that the bushings (8) have to be changed. Using a hammer and a brass drift, drive the bushings (8) out of the idler wheel (2). Make sure you do not damage the idler wheel seal bore.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-11
Assembly
STEP 3 7
STEP 1
4 7
A
8
8
4 CS02B521
Install the remaining O-rings and remaining face seal (7) metal bushing in the slider seal bore (4). Apply clean oil copiously to the face seals.
2 8
STEP 4
2
3 4 CS02B524
A.
Clean the inside
Carefully install the bushings (8) in the idler wheel using a press and a suitable rod.
6 5
STEP 2 2
7
CS02B520
7
2
Lubricate the O-rings (5) with clean grease. Install an O-ring on the shaft (6), then install the shaft in the hub (4). Secure the slider and the shaft with a retainer pin (3).
7 7 CS02B522
Install an O-ring and a face seal metal bushing in the idler wheel bore (2). Apply clean oil to the face seal lips. Repeat this step to install the face seal on the other side of the idler wheel.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-12
STEP 5
STEP 8 2
5
2
1
6 4
4 CS02B519
Apply clean grease around the shaft (6). Install the shaft and slide (4) assembly in the idler wheel (2).
CS02B517
Fill the idler wheel (2) with clean oil (see specifications). Install the drain plug (1) in the slide (4).
STEP 6
6 3 4
2
5 1 CS02B572
Apply clean grease on the O-ring (5) if this has not already been done and install the O-ring on the shaft (6). Install the slide (4) on the shaft and install a retainer pin (3) to fasten the slide and the shaft. Install a drain plug (1). NOTE: Check the pitch of the retaining ports of the tension shock absorber yoke, see page 8.
STEP 7 Check for leaks to ensure that the idler wheel has been correctly reassembled and check for any damage which could give rise to leaks at seals and other components.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-13
Leakage test
STEP 5
Use CAS 1450 and CAS 1682 for the leak checks shown below.
Make sure that the shut-off valve (1) is open.
STEP 6 Open the pressure regulator (2) until the pressure gauge shows 1.9 bar.
1
STEP 7 The shaft being checked should now be rotated four times.
STEP 8 Close the regulator until the pressure gauge shows 1 bar.
2
STEP 9 B407320M
STEP 1 Connect the shut-off valve (1) to the pressure regulator (2). Connect a union for the air supply hose to the shutoff valve.
Close the shut-off valve. Maintain the air pressure of Step 8 for 10 seconds. A reduction in air pressure during this period shows a defective component or incorrect assembling.
STEP 2 Install the adaptor and a quick coupler to the oil filler orifice. Install a seal with the adaptor.
STEP 3 Turn the knob anti-clockwise to close the pressure regulator (2).
STEP 4 Connect the pressure gauge pipe to the quick coupler.
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-14
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER Description
1
5
4
3
2
CI02B500
1 SHOCK ABSORBER SPRING 2 RETAINER PIN 3 SLOTTED NUT
Lep SM4605005-0EN
4 COMPENSATOR 5 SPRING GUIDE
Issued 09-07
Copyright © 5005-15
Disassembly
Assembly
STEP 1
STEP 1
Clean the shock absorber - spring assembly.
Fix the spring guide (5) in a hydraulic press.
!
WARNING: The shock absorber spring is highly compressed.
STEP 2
STEP 2 Place the shock absorber spring (1) and the compensator (4) in the hydraulic press on the spring guide (5).
STEP 3 Operate the hydraulic press to compress the shock absorber spring (see specifications for the value).
1
STEP 4 Install the slotted nut (3) and install a new retainer pin (2) in the slotted nut and the spring guide shaft (5).
STEP 5 Remove the shock absorber spring from the hydraulic press. CS02E656
Place the shock absorber spring in a hydraulic press. Use the press to compress the shock absorber spring (1).
STEP 3 Drive out the retainer pin (2) from the slotted nut (3). Remove the slotted nut from the spring guide (5).
STEP 4 Operate the hydraulic press so as to very slowly release tension in the shock absorber spring (1).
STEP 5 Remove the compensator (4) and the shock absorber spring (1) from the spring guide (5).
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-16
TRACK TENSION CYLINDER Description
1 2
3 15 14 12
4
13
5
11 7 6 8 9
10 JS01084A
1 2 3 4 5 6 7 8
SCREW FLAT WASHER SCREW LOCKING WASHER BRACKET GREASE FITTING CHECK VALVE SPRING
Lep SM4605005-0EN
9 10 11 12 13 14 15
BALL NON-RETURN CHECK VALVE BODY CYLINDER ROD WIPER SEAL THRUST RING O-RING CYLINDER BARREL
Issued 09-07
Copyright © 5005-17
Removal
STEP 3
NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
STEP 1
A
JD01082A
JD01080A
Using a crowbar, push the track tension cylinder piston rod into the cylinder barrel. The grease will flow out of the non-return check valve pressure release orifice. Remove the track tension cylinder from the machine.
See Section 5003 "Removal of the lower roller" and remove the roller (A) located under the track tension cylinder.
Disassembly
STEP 2
Using a suitable cleaning solvent and clean cloths, remove impurities and grease from the outside of the track tension cylinder.
STEP 1
STEP 2 Remove the two screws (3) and the locking washers (4). Remove the bracket (5).
STEP 3 Remove the grease fitting (6) from the non-return check valve.
STEP 4 JD01081A
NOTE: Do not allow any part of your body to pass under the tension cylinder. You could be seriously injured by the tension cylinder falling, when the screws are removed which fasten it to the machine. Unscrew the non-return check valve. As soon as the grease starts to flow, stop unscrewing the tension cylinder check valve. Place wooden blocks under the tension cylinder to prevent it falling off the machine when the two screws which attach it to the machine are removed. Remove the two screws and the flat washers (2).
Lep SM4605005-0EN
Remove the non-return check valve from the cylinder barrel (15).
STEP 5 If necessary, disassemble the non-return check valve by removing the check valve (7), spring (8) and the ball (9) from the non-return check valve (10).
Issued 09-07
Copyright © 5005-18
Assembly
STEP 6
STEP 1
11
12
14
Apply clean grease to a new O-ring (14) and new thrust ring (13). Install the O-ring and the thrust ring in the cylinder barrel (15).
15
STEP 2
A 13 JS01083A
Remove the cylinder rod (11) from the cylinder barrel (15).
STEP 7 Using a screwdriver, remove the wiper seal (12) from the cylinder barrel (15). Scrap the wiper seal.
STEP 8 Remove and scrap the thrust ring (13) and the O-ring (14).
Inspection STEP 1 Clean all the components with cleaning solvent.
STEP 2
JS00372A
Apply clean grease to a new wiper seal (12). Using a hammer and a sleeve (A), drive the wiper seal into the cylinder barrel (15) with the lip orientated towards the outside of the cylinder barrel. Drive the wiper seal into the cylinder barrel until it touches the cylinder barrel shoulder. Apply clean grease to the wiper seal lip.
STEP 3 Apply clean grease around the cylinder rod (11). Install the cylinder rod in the cylinder barrel (15).
Check for deep grooves, scratches or other damage inside the cylinder. If necessary, use a lamp to look inside the cylinder. Use medium abrasive emery paper to eliminate grooves or scratches. If the grooves or scratches are too deep or if there is other damage, change the cylinder.
STEP 4
STEP 3
STEP 5
Check for deep grooves, scratches or other signs of wear or damage on the cylinder rod. Use medium abrasive emery paper to eliminate grooves or scratches. If the cylinder rod is worn or damaged, replace the cylinder rod.
Install the non-return check valve assembly on the cylinder barrel (15). Tighten the non-return check valve to torque (see specifications).
STEP 4 Check for wear or damage on the non-return check valve assembly. Check for signs of irreparable seizure of the spring. Change all defective components.
Lep SM4605005-0EN
If the non-return check valve has been disassembled, install the ball (9), spring (8) and check valve (7) in the non-return check valve body (10). Install the grease fitting (6) in the non-return check valve body.
STEP 6 Install the bracket (5) on the cylinder barrel (15). Install two locking washers (4) and screws (3) to fasten the bracket to the cylinder barrel.
Issued 09-07
Copyright © 5005-19
Installation
STEP 3
NOTE: The photos below do not correspond to the machine model, but the procedure is the same.
STEP 1 Check that the cylinder rod (11) is driven as far as possible into the cylinder barrel (15).
STEP 2 A JD01080A
See "Installation of the lower roller" for installing the roller (A) under the track tension cylinder.
JD01082A
1
JD01081A
Move the tension cylinder into position. Apply Loctite 262 to the threads of the two screws (1). Support the tension cylinder while an assistant installs two flat washers (2) and screws (1) to fasten the tension cylinder. Tighten the screws to torque (see specifications).
Lep SM4605005-0EN
Issued 09-07
Copyright © 5005-20
NOTES ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ........................................................................................................................................................................................................................................... ...........................................................................................................................................................................................................................................
Lep SM4605005-0EN
Issued 09-07
6001
Copyright ©
Section 6001 REMOVAL AND INSTALLATION OF THE TRAVEL-MOTOR REDUCTION GEAR ASSEMBLY
CNH
Lep SM4606001-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 6001-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS ...................................................................................................................................... 2 TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY ...................................................................................................... 3 Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS Hydraulic fluid.........................................................................................................................................See Section 1002 Lubricant for reducing gear pinion Type....................................................................................................................................................See Section 1002 Quantity.............................................................................................................................................. See Section 1002 Weight of the travel motor/reduction gear assembly ..............................................................................See Section 1002
SPECIAL TORQUE SETTINGS Travel motor/reduction gear assembly to track frame retaining screw ...................................................See Section 1002 (apply Loctite 262 to the screw threads) Drain plug, oil filling and oil level plug ........................................................147.1 ± 14.7 Nm (108.49 lbf-ft) ± (10.84 lbf-ft) (put Teflon tape around the threads)
Lep SM4606001-0EN
Issued 09-07
Copyright © 6001-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY Removal and installation STEP 1
STEP 5 To prevent any fluid leaks when disconnecting hydraulic lines, connect a vacuum pump to the hydraulic reservoir (see Section 8000).
STEP 6
1 1 JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 3
CD00F067
Remove the four screws and washers (1) then remove the access panel to the travel motor.
STEP 7
1 2
1 CD01K026
CD02B005
Remove the oil filler plug and the oil level plug (1) and the drain plug (2) and drain the oil.
To facilitate reassembly, attach identification tags to the different hoses connected to the travel motor (1).
NOTE: When installing, refer to Section 1002 for the recommended quantity and type of oil. Tighten the plugs to a torque of 147.7 ±14.7 Nm (108.49 lbf-ft) ± (10.84 lbf-ft).
STEP 8 Start the vacuum pump.
STEP 4 Put Teflon tape around the plug thread and put it back in place. Install the filling plug.
Lep SM4606001-0EN
Issued 09-07
Copyright © 6001-4
STEP 9
STEP 13
1 2 CD02B005
Disconnect the hoses (1) from the travel motor (2). Plug the hoses and the unions.
STEP 10 Stop the vacuum pump.
JD00838A
Remove the retaining screws from the travel motor/ reduction gear assembly of the undercarriage. Remove the travel motor/reduction gear assembly from the machine.
STEP 11
NOTE: When installing, tighten the screws to the torque specified in Section 1002.
Refer to Section 5004 and carry out the steps for the removal of the sprocket wheel.
STEP 14
STEP 12
6002-11
JD00836A
Connect a suitable lifting device to the travel motor/ reduction gear assembly. NOTE: See Section 1002 for the weight of the travel motor/reduction gear assembly.
Lep SM4606001-0EN
Place the travel motor/reduction gear assembly on a flat surface with the drive motor turned upwards. Remove the lifting equipment. NOTE: When installing, follow the same procedure in the reverse order. Replace all O-rings with new O-rings. Fill the housing with hydraulic oil using the leak return port. Before operating the machine, check the circuit for leaks. Check the hydraulic oil level in the reservoir and the oil level in the housing of the travel reduction gear, top up if necessary.
Issued 09-07
Copyright ©
6003
Section 6003 REMOVAL AND INSTALLATION OF THE SWING REDUCTION GEAR
CNH
Lep SM4606003-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 6003-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS...................................................................................................................................... 2 TOOLS REQUIRED ........................................................................................................................................................ 2 SWING REDUCTION GEAR........................................................................................................................................... 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 4
SPECIFICATIONS Swing motor and swing reduction gear Weight ............................................................................................................................................... See Section 1002 Swing reduction gear Capacity ............................................................................................................................................ See Section 1002 Type of oil .......................................................................................................................................... See Section 1002
SPECIAL TORQUE SETTINGS Swing motor retaining screws on swing reduction gear .............................. 294 to 336 Nm (216.84 lbf-ft to 247.82 lbf-ft) Screws which attach the swing reduction gear to the upperstructure frame900 to 1050 Nm (663.80 lbf-ft to 774.43 lbf-ft)
TOOLS REQUIRED - Hand pump CAS-10090
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-3
SWING REDUCTION GEAR Removal
STEP 5
STEP 1 Carry out Steps 1 to 10 of "Removal of the swing motor" (see Section 8008).
STEP 2
1 JD00437A
2
Carefully lift the upperstructure swing motor and reduction gear assembly, move it away from the machine.
STEP 6 CD02E001
Attach an identification tag to the hoses (1) and (2), disconnect them and plug the ports.
STEP 3 Mark the position of the swing reduction gear on the upperstructure frame by making alignment marks on the swing reduction gear and the upperstructure frame.
STEP 4 1 JS00379A
Place a container of 15 litres capacity under the swing reduction gear drain plug. Remove the drain plug (1) and drain the oil. Install the drain plug.
1
JD00449A
Remove the swing reduction gear retaining screws (1) and the centring pin.
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-4
STEP 7
Installation
Lower the swing motor/reduction gear assembly to the ground and place it on suitable stands.
STEP 1
NOTE: The stands must be high enough to prevent the pinion touching the ground.
STEP 8
2
1 JD00446A
Connect a suitable lifting device to the swing motor and move it into position above the reduction gear. Carefully lower the swing motor onto the reduction gear. JD00386A
STEP 2
To facilitate reassembly, make an alignment mark (1) on the swing motor and on the reduction gear. Remove the swing motor retaining screws (2).
STEP 9 Carefully raise the swing motor and move it away from the swing reduction gear. Place it in a clean area.
1
JD00386A
Install the swing motor retaining screws (1). NOTE: Tighten the screws to torque.
STEP 3 Clean the upperstructure mating surface.
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-5
STEP 4
STEP 6
B A AA
JD00437A
JD00473A
Raise the swing motor/reduction gear assembly off the ground. Apply No. 2 EP lithium grease over the pinion (A).
Connect the hand pump CAS-10090 to the swing motor brake release orifice (A).
NOTE: Before installing the swing motor/reduction gear assembly, check that the drain hose (B) is installed on the side of the reduction gear housing.
Check that the hand pump is filled with fluid.
STEP 7 STEP 8 Operate the hand pump until the pressure gauge shows 29 bar. The swing motor brake should be released, thus allowing the reduction gear output shaft to turn.
STEP 5
STEP 9 Lower the swing motor/reduction gear assembly onto the upperstructure mating surface, using a dowel pin. NOTE: Make sure that the reduction gear output gear is correctly engaged in the upperstructure crown wheel.
STEP 10
JD00385A
Raise the swing motor/reduction gear assembly and bring it into position above the upperstructure mating surface, ensuring that it is in line with the alignment marks previously made.
1
JD00449A
Apply Loctite 262 to the screw threads (1) and tighten them to the torque specified in Section 1002.
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-6
STEP 11
Fill the swing reduction gear with the quantity (capacity) and type of oil specified in Section 1002. Install the oil dipstick and check the oil level. The oil level should be on the lower part of the dipstick. Add oil as required and install and tighten the oil filler plug.
STEP 13 A 1 2 JD00473A
Release the hydraulic pressure in the hand pump CAS10090 and disconnect it from the swing motor brake release orifice (A). Remove the lifting equipment from the swing motor.
STEP 12
CT07A028
1 2
3
AIR BLEED PLUG LUBRICATION ORIFICE
Remove the air bleed plug on the side of the swing reduction gear. Pump No. 2 EP lithium grease into the reduction gear until grease comes out of the air bleed orifice. Install the air bleed plug.
STEP 14 2
Connect a vacuum pump to the hydraulic reservoir (see Section 8000). Start the vacuum pump.
CT07A010
1
CT07A041
Check that the swing reduction gear oil drain plug (1) is correctly tightened. Remove the oil level dipstick (2) and the oil filler plug (3).
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-7
STEP 15
STEP 18
1 2
CD02B034
CT07A009
Remove the plugs and connect the hoses (1) and (2).
Connect the earth cable to the battery.
STEP 16
STEP 19
Refer to the removal of the hydraulic swing motor and carry out Step 8 in the reverse order.
See Section 8001 and adjust the swing motor secondary relief valves.
STEP 17
STEP 20
Stop and disconnect the vacuum pump from the hydraulic reservoir (see Section 8000).
1 2
CS02B555
Install the upper panel (1) using retaining screws (2). NOTE: Before operating the machine, start the engine, check the system for leaks and check the fluid level in the hydraulic reservoir, top up if necessary.
Lep SM4606003-0EN
Issued 09-07
Copyright © 6003-8
NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................
Lep SM4606003-0EN
Issued 09-07
Copyright ©
Section
SWING REDUCTION GEAR DISASSEMBLY AND ASSEMBLY
CNH
Lep SM4606004-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
6004
6004
Copyright © 6004-2
TABLE OF CONTENTS SPECIAL TORQUE SETTINGS...................................................................................................................................... 2 SWING REDUCTION GEAR........................................................................................................................................... 3 Description ................................................................................................................................................................. 3 Disassembly ............................................................................................................................................................... 4 Assembly ................................................................................................................................................................... 7
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-3
SWING REDUCTION GEAR Description
13
15
14
16
12 21
17 18
11 10
19
9
8
6
20
4
5
2
3
1 7
CI02B502
1 2 3 4 5 6 7 8 9 10 11
PINION SPACER SNAP RING PLATE SPHERICAL ROLLER BEARING HOUSING SHAFT LIP-SEAL SPACER SPHERICAL ROLLER BEARING PIN
Lep SM4606004-0EN
12 13 14 15 16 17 18 19 20 21
RING GEAR FIRST STAGE SUN GEAR SHIM FIRST STAGE PLANETARY GEAR FIRST STAGE PLANET WHEEL CARRIER SECOND STAGE PLANETARY GEAR RETAINER PIN SECOND STAGE PLANET WHEEL CARRIER SPACER SECOND STAGE SUN GEAR
Issued 09-07
Copyright © 6004-4
Disassembly
STEP 4
NOTE: The swing reduction gear is extremely heavy. Use suitable lifting equipment to lift and move the components.
1
NOTE: The photos below do not correspond to the machine model, but the procedure remains the same.
STEP 1 Place the reduction gear in a clean working area.
STEP 2
CD02B037
Remove the second stage sun gear (1).
STEP 5 1
1 CD02B035
Remove the first stage sun gear (1) and thrust ring.
STEP 3
1
CD02B038
Remove the second stage planet wheel carrier (1).
CD02B036
Remove the first stage planet wheel carrier (1).
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-5
STEP 6
STEP 8 4
3
5 6 7
1 2 2
1
6003-090
Remove the ring gear (1) from the reduction gear housing (2) using the notch in the housing for leverage. NOTE: The planetary gear axles are assembled in two ways: A = assembly by hubbing the axle; B = assembly by blocking the axle (roll pin). According to the type of assembly, replace the entire planet wheel carrier or individual spare parts.
JD01465A
Remove the two screws (1), the brake plate (2), the end plate (3) and the pinion (4). Remove the snap ring (5), the stop (6) and the plate (7).
STEP 9
STEP 7 1 2 3 6003-096
Install the swing reduction gear in a suitable press. Place shims under the flange on the housing to hold the shaft upright. JD01464A
STEP 10
Turn the swing reduction gear upside down to be able to access the pinion (1). Straighten up the corners of the brake plate (2) to free the screws (3).
2 1
A 6003-097
Place a jack (A) under the shaft (1) and the bearing (2) under the press to hold and support the shaft when it has been pressed out of the housing. Press the shaft from the housing. Remove the shaft and the bearings from the press.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-6
STEP 11
STEP 13
1
3 1
CD02B039
Remove the roller bearing (1) from the gear housing.
4 2
2
STEP 12
CI02B503
Place the shaft (1) under a press. Insert two shims (2), press the shaft (1) from the bearings (3). Remove the spacer (4).
1
STEP 14
JD00459A
Using a suitable tool remove the lip seal (1) from the gear housing. Discard the lip seal.
1 CD02B040
Place the planetary gear assembly on a workbench. Press the retainer pins (1) in the axles just enough to remove the axles.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-7
Assembly
STEP 15 2
NOTE: The photos below do not correspond to the machine model, but the procedure remains the same.
STEP 1 Place the planet wheel carrier on a clean workbench.
STEP 2 1
2
1
CD02B041
Support the planetary gears and remove the axles from the planet wheel carrier (2). Press the pins completely from the axles (1). Remove the pins.
STEP 16 6003-106
Assemble the planetary gears (1), slide the thrust washers (2) under the pinions (boom).
STEP 3 1 1
6003-105
Remove the planetary gears (1).
STEP 17 1 6003-105
Align the pinions with the bores of the planet wheel carrier and install the axles. Take care to position the axle retaining bore correctly (1) with respect to the bore of the planet wheel carrier.
6003-106
Remove the thrust washers (1) from the planetary gears.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-8
STEP 4
STEP 6
B
!
WARNING: Take precautions (gloves), risk of burns.
A 2
3 6003-107
Install a new pin (A) in the shaft using a suitable tool. Recess dimension in the planet wheel carrier: B = 1 mm. Lock it, using two strokes of a punch.
1
STEP 5 Position the retainer pins in the second stage planet wheel carrier.
CI02B504
Install the spacer (1) on the shaft (2). Heat the bearing (3) to 50°C above the ambient temperature. Assemble the hot bearing on the shaft (2), use protective gloves.
STEP 7
CS00K512
Boom: direction of rotation.
JD00465A
Degrease the reduction gear housing and apply Loctite 504. Fix the reduction gear housing in a press, install the lip seal in the reduction gear housing. Lubricate the lip seal with No. 2 EP lithium grease. Install the spacers, then install the bearing on the reduction gear side.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-9
STEP 8
STEP 10
6
1
6 5
1
2
7
1
JD00469A
Degrease the mating surfaces of the gear housing, ring gear and the four dowel pins. Install the four dowel pins (1) into the gear housing. Apply Loctite 504 liquid packing to the mating surfaces.
3 4
4
STEP 11 CI02B505
Coat the roller bearings (1) with 800 grams of No. 2 EP lithium grease (2). Place the shaft assembled (3) on the shims (4) under a press. Position the housing (5) equipped with the bearing and the lip seal on the shaft (3). Position the shims (6) on the bearing (7). Assemble the housing using the press (booms).
2
STEP 9 1
1
JD00470A
Install the ring gear (1) ensuring the alignment marks are aligned. Assemble four screws (2) in opposition to hold the ring gear (1).
2 3
4 5
7
6 CI02B506
Assemble the plate (1). Assemble the snap ring (2) with a gap of about 30 mm with respect to the notch on the housing. Install the spacer (3). Lubricate and assemble the pinion (4). Assemble the stop plate (5). Install the brake plate (6), assemble and tighten the screws (7). Bend the corners of the brake plate (6) on the screw heads (7).
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-10
STEP 12
STEP 14 1 1
CD02B038
Install the second stage planet wheel carrier (1) so that it meshes correctly with the internal teeth of the ring gear. Turn the planetary assembly slightly to engage the splines of the pinion shaft.
STEP 13
CD02B036
Install the first stage planetary assembly (1) so that it meshes with the internal teeth of the ring gear. Turn the planetary assembly slightly to mesh the teeth of the planetary gears with the teeth of the second stage sun gear.
STEP 15 1
1 CD02B037
Install the second stage sun gear (1) so that it meshes with the planetary gear assembly.
Lep SM4606004-0EN
CD02B035
Install the thrust shim on the second stage sun gear. Install the first stage sun gear (1) so that it meshes correctly with the teeth of the planetary gears. Turn the first stage planetary assembly by hand and check that the output shaft rotates smoothly.
Issued 09-07
Copyright © 6004-11
STEP 16 A
CS00K516.
Measure the dimension (A), position of the sun gear. Make sure that the distance between the end surface of the sun gear No.1 (13) and the ring gear (12) is 3.653 to 5.66 mm. If the distance falls short of reaching 3.653 mm: Gear shaft (7) and the roller bearing (5) are dislocated. The roller bearing (10) is not inserted completely. Foreign substances are engaged. If the distance is larger than 5.66 mm: The wire (3) is not installed properly. The ring gear (12) is not completely tightened into the gear case (6). Foreign substances are engaged.
Lep SM4606004-0EN
Issued 09-07
Copyright © 6004-12
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4606004-0EN
Issued 09-07
Copyright ©
Section 6005
ASSEMBLY AND DISASSEMBLY
CNH
Lep SM4606005-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
6005
TRAVEL REDUCTION GEAR
Copyright © 6005-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 SPECIAL TORQUES ...................................................................................................................................................... 2 REDUCTION GEAR........................................................................................................................................................ 3 Description .................................................................................................................................................................. 3 Disassembly................................................................................................................................................................ 4 Inspection.................................................................................................................................................................... 9 Assembly .................................................................................................................................................................. 10
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
SPECIFICATIONS See Section 1002.
SPECIAL TORQUES Screw *(4).............................................................................................................. 461 ± 44.1 Nm (340.01 ± 32.52 lbf-ft) Screw *(6) ............................................................................................................. 53.9 ± 5.9 Nm (39.75 ± 4.35 lbf-ft) Screw *(28)..................................................................................................................68.6 ± 6.9 Nm (50.60 ± 5.09 lbf-ft) Plug (29).................................................................................................................147 ± 14.7 Nm (108.42 ± 10.84 lbf-ft) * .............................................................................................................................................(With applying Loctite #242)
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-3
REDUCTION GEAR Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
HOUSING BEARING RING GEAR SCREW COVER SCREW FLOATING SEAL SHIM LOCK WASHER SUPPORT RING CARRIER 2 PLANETARY GEAR 2 RETAINING RING BEARING CARRIER PIN 2
Lep SM4606005-0EN
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
SPRING PIN SPACER SUN GEAR 2 CARRIER 1 PLANETARY GEAR 1 THRUST WASHER 1 NEEDLE BEARING CARRIER PIN 1 SPRING PIN SUN GEAR 1 THRUST PLATE COVER SCREW PLUG O-RING
Issued 09-07
Copyright © 6005-4
Disassembly General precautions 1. It’s common that a reduction unit which has been dismounted from the machine is covered with dirt or dust. Wash and dry the exterior of the unit. 2. Loosen the drain and filler plug (29) to drain oil in the reduction unit.
!
!
WARNING: Safety is priority while disassembling. Be careful and avoid hands from being caught between parts or lifted parts from falling on your feet.
STEP 2
WARNING: If the oil is still hot, internal pressure still remains. Care should be taken because the oil can blow out.
3. Placing counter marks. Place counter marks on the outer side of each mating face in order to put the faces back into their original locations when assembling. NOTE: Numbers in parentheses following the part names shown in the description below correspond to symbols in the structural drawings.
STEP 1
Remove the srews (28) that secure cover (27).
STEP 3
As the cover (27) is adhered to ring gear (3), remove cover (27) by lightly hammering slantwise upward by wooden bar aiming at projection of cover (23).
Remove the screws (28) at 3 places from cover (27) almost equally apart each other, then install M12 eye bolts. Lift up the unit using them and place it on work stand with cover (27) upward.
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-5
STEP 4
Remove thrust plate (26). Screw three M10 eye bolts in carrier 1 (19) and lift up and remove carrier 1 as sub-ass'y (19), (20), (21), (22), (23), (24). Remove sun gear 1 (25).
STEP 7
Remove the lock washer (9) by placing a screwdriver or equivalent to the washer’s split part and tapping the driver with a hammer.
STEP 8
STEP 5
Remove sun gear 2 (18). Screw three M10 eye bolts in carrier 2 (11) and lift up and remove carrier 2 as sub-assembly (11), (12), (13), (14), (15), (16) and (17).
STEP 6
Screw three M12 eye bolts in ring gear (3) almost equally apart each other, then lift it up horizontally and remove housing assembly including ring gear (3), housing (1), angular bearing (2), seal cover (5), floating seal (7) and screws (4) together.
Remove the support ring (10).
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-6
STEP 12
OVER 300
STEP 9
Screw three M24 eye bolts in housing (1) almost equally apart each other. Lift up the housing assembly and place it on work stand with housing (1) upward. Put a mating mark outside of housing (1) and ring gear (3). NOTE: Take care not to damage the sliding surface of floating seal (5) or its O-ring. Bearings (2) have been tightly press fitted in housing (1). Don't remove the bearings (2) unless otherwise their exchange is needed. In case bearings (2) removed, don't re-use them. New bearings (2) should be used and shim (8) adjusting be required.
STEP 10
Knock spring pins 6 x 36 (24) fully into carrier pins 1 (23). Tap carrier pins 1 (23) out from carrier 1 (19). Remove thrust washers 1 (21), planetary gears 1 (20) and needle bearings (22) from carrier 1 (19). NOTE: When carrier pins 1 (23) are to be re-used, mark each pin with its mated hole of carrier 1 (19) to assure the same combination as before.
Remove floating seal (7) from seal cover (5). Remove the srews (6), and remove seal cover (5) from housing (1). Remove the screws (4), leaving two of them diagonally. Loosen the other screws (4) and tap lightly the head of them then ring gear (3) can be easily removed from housing (1).
STEP 11 Remove a piece of floating seal (7) of motor side.
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-7
STEP 13
STEP 14
Knock out spring pins 6 x 36 (24) from carrier pins 1 (23) for re-assembling. NOTE: When carrier pin 1 (23) or planetary gear 1 (20) is needed to be exchanged, three pins or three gears should be all exchanged.
Knock spring pins 10 x 63 (16) fully into carrier pins 2 (15). Tap carrier pins 2 (15) out from carrier 2 (11). NOTE: When carrier pins 2 (15) are to be re-used, mark each pin with its mated hole of carrier 2 (11) to assure the same combination as before.
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-8
STEP 15
Inspection 1. Thrust washers Inspect if there is any seizure, abnormal wear, uneven wear, or other. Check that the wear is within allowable values. 2. Gears Check for pitching and seizure on the face of tooth. Check the colour on the root of tooth to find out cracks. 3. Bearing Make sure that there are no noises or engagement by manually rotating the bearing. 4. Floating seal Check if there is any damage on the sliding faces of O-rings.
Remove planetary gears 2 (12), bearing (14) and retaining ring C-type (13) from carrier 2 (11). Remove spacer (17) from carrier 2 (11). Knock out spring pins 10 x 63 (16) from carrier pins 2 (15) for re-assembling. NOTE: Take great care not to pinch your hand between gears and carrier 2 (11) while disassembling. NOTE: When carrier pin 2 (15) or planetary gear 2 (12) is needed to be exchanged, three pins or three gears should be all exchanged.
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-9
Mark
Item
Reference value (mm)
Allowable value (mm)
Remedy
A
Wear on the planetary shaft
Smooth, no abnormal wear and seizure
Smooth, no abnormal wear and seizure
Replace 3 pieces as a set
B
Conditions on face of tooth and root of tooth
Smooth, no abnormal wear and seizure
No pitching of dia. 1.6 or more, no cracks on the root of tooth
Replace (Replace 3 pieces as a set for planetary gears)
C
Thrust spaces in the inner race of angular bearings (2)
- 0.08 to 0.02
- 0.08 to 0.02
Adjust shim thickness (see page 12)
D
Thickness of thrust washer 1 (21)
From 3.9 mm To 4.1 mm
0.1 of wear
Replace
E
Thickness of spacer (17)
From 4.2 mm To 4.6 mm
0.15 of wear
Replace
F
Thickness of thrust plate (26)
From 4.34 mm To 4.66 mm
0.15 of wear
Replace
G
Lubrication oil
2,000 working hours (engine hour meter)
Lep SM4606005-0EN
Replace
Issued 09-07
Copyright © 6005-10
Assembly
STEP 3
General precautions 1. Wash each part with treated oil, then dry it completely with air. For the surfaces to which Loctite is applied, degrease with thinner or equivalent. 2. Check for any abnormality on each part. 3. Tighten hexagonal socket head cap screws upon application of Loctite. 4. Apply a thin coat of gear oil to assembly parts prior to the assembly.
!
WARNING: Be careful and avoid hands from being caught between parts or lifted parts from falling on your feet.
SLOT DIRECTION TURNS
CALK TWO PLACES
TO COVER SIDE
180° DEGREE POSITION
STEP 1
COVER SPRING PIN OF 5 mm BY CALKING
SINK SPRING PIN OF 1 to 2 mm FROM SURFACE
PINION
Calk carrier 2 (11) on diagonally position to prevent spring pin 10 x 63 (16) from coming out. Install spacer (17), planetary gears 2 (12), bearings (14) and retaining ring C-type (13) into carrier 2 (11).
NOTE: Refer to "Detail of calking
STEP 4
STEP 2
Install carrier pins 2 (15) into carrier 2 (11) where the holes for spring pins 10 x 63 (16) are to be in line with those of carrier 2 (11). Install spring pins 10 x 63 (16) into carrier 2 (11) and at the same time into carrier pins 2 (15). (Sink spring pins of 1 - 2 mm from surface).
Lep SM4606005-0EN
Install planetary gears 1 (20), needle bearings (22) and thrust washers 1 (21) into carrier 1 (19).
Issued 09-07
Copyright © 6005-11
STEP 5 CORRECT
Install carrier pins 1 (23) into carrier 1 (19) where the holes for spring pins are to be in line with those of carrier 1 (19). Install spring pins 6 x 36 (24) into carrier 1 (19) and at the same time into carrier pins 1 (23). (Sink spring pins of 1 - 2 mm from surface)
STEP 6
INCORRECT
INCORRECT
NOTE: Clean the groove for floating seals (7) to eliminate oil, dust, paint or other foreign material. NOTE: Apply gear oil slightly on sliding surfaces of floating seals (7) before assembling but strictly dry on O-rings and on its grooves NOTE: Confirm that O-ring of floating seals (7) are not twisted and that floating seals are correctly installed. i.e. parallel as shown each other between seal cover (5) and motor casing after assembled. It is recommended to use jig to install floating seal
STEP 8 LOCTITE No. 515
Calk carrier 1 (19) on diagonally position to prevent spring pin 6 x 36 (24) from coming out. NOTE: Refer to "Detail of calking" (See step 3).
STEP 7
Apply Loctite No. 515 to the mating surfaces of housing (1) and ring gear (3) without a gap. Install seal cover (5) on housing (1). Then, after applying Loctite #242 on the threads of 16 pieces of screws M10 x 25 (6) without removing rust preventive agent, tighten them with torque wrench. Tightening torque of screw M10 x 25 (6) is 53.9 ± 5.9Nm (39.75 lbf-ft ± 4.35 lbf-ft). NOTE: Refer to below "How to apply Loctite #242".
Install main bearing (2) to inner surface of housing (1). Install a piece of floating seal (7) on motor casing and also install another piece of floating seal (7) on seal cover (5). Soak 20mm length from the tip of bolt in loctite #242
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-12
STEP 9
STEP 11 LOCTITE No. 515
NOTE: This process is necessary when any motor (casing), housing (1), bearing (2) or lock washer (9) is changed. As this is not the case, use the old shims (8) as they are.
Apply Loctite #515 on mating surfaces of housing (1) and ring gear (3) without a gap.
STEP 10
1. Fit in two bearings (2) on housing (1) pressing their outer laces 2. Press inner laces of two bearings (2) lightly and evenly, measure the assembling width "A" of inner laces. NOTE: When measuring the assembling width "A", rotate bearings (2) at least 5 times and become the width "A" stably. Install three M24 eye bolts equally apart on housing (1). Using the eye bolts, hang the housing (1) by wire rope and place it on ring gear (3), coinciding mating marks. After applying Loctite #242 on the threads of 26 pieces of screws M20 x 120 (4) without removing rust preventive agent tighten them with torque wrench. Tightening torque of screw M20 x 120 (4) is 461± 44.1N-m (340.01 lbf-ft±32.5 lbf-ft).
3. Measure the motor side assembling width "B" for bearings (2).
NOTE: Refer to step 8, "How to apply Loctite #242".
6. Suppose the thickness of a shim (8) to be used is S, the space X is expressed as follows: X = (B + C) - (A + D + S)
4. Measure the groove width "C" of motor casing. 5. Measure the thickness "D" of lock washers (9). NOTE: Measure them at 4 places evenly apart on the circumferences then calculate and use those mean values. Measure them to the accuracy of 0.01 mm.
7. Select a shim (6) so as the clearance X to come to 0.08 mm (interference) - +0.02 mm (clearance) on this unit.
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-13
STEP 12
STEP 15
Place motor on work stand with the shaft upward, and put the selected shim (8) (Refer to step 11, page12) on the bearing mating surface of motor casing.
STEP 13 Press
Install support ring (10) over outside of lock washers (9).
STEP 16
Install three M12 eye bolts on ring gear (3) almost equally apart and lift it up. Descend it concentric with motor and put bearings (2) on housing (1) into motor casing. Use press machine and press inner lace of bearing (2) into full depth.
STEP 14 Install three M10 eye bolts equally apart on carrier 2 (11). Using the eye bolts, hang the carrier 2 assembly by wire rope and place three planetary gears 2 (12), put carrier 2 assembly into ring gear (3) and mesh the splines to those of motor. NOTE: Positioning carrier 2 assembly is important to obtain better lubrication (see the figure below). Carrier 2
Planetary gear 2
While pressing inner lace of bearing (2), install lock washers (9) into groove.
Motor port
Lep SM4606005-0EN
Issued 09-07
Copyright © 6005-14
STEP 17
STEP 20
Insert and mesh sun gear 2 (18) on center.
LOCTITE No. 515
STEP 18
Apply Loctite No. 515 on mating surfaces of cover (27) and ring gear (3), and install the cover (27) on ring gear (3).
Install three M10 eye bolts equally apart on carrier 1 (19). Using the eye bolts, hang the carrier 1 assembly by wire rope and place it in ring gear (3), rotate planetary gears 1 (20) by hand and adjust carrier 1 (19) to mesh with sun gear 2 (18). Making sure that coupling is on the shaft end, install sun gear 1 (25) on center.
NOTE: Gear oil can be filled before installing cover (27) if you can measure prescribed volume of oil. NOTE: Refer to Step 8, page 11 "How to apply Loctite #242".
STEP 21
STEP 19
Cover
Sharp edge
R
Thrust plate
Apply Loctite No. 242 to the screws (28) and fasten them with tightening torque of 68.6 ±6.9 Nm (50.60 lbfft ± 5.08 lbf-ft).
STEP 22 Fill gear oil (GEAR 135H EP)15 litters from two G3/4 ports. Place thrust plate (26) on carrier 1 (19).
STEP 23
NOTE: Face sharp edged side to cover (27) (see the figure above).
Tighten taper screw plugs (29) to a torque of 147.1 ± 14.7N-m (108.49±10.84 lbf-ft).
Lep SM4606005-0EN
Issued 09-07
Copyright ©
Section 8000 DEPRESSURISING AND DECONTAMINATING THE HYDRAULIC SYSTEM, USE OF THE VACUUM PUMP
CNH
Lep SM4608000-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8000
AND BLEEDING THE COMPONENTS
Copyright © 8000-2
TABLE OF CONTENTS SPECIAL TOOLS ............................................................................................................................................................ 3 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM............................................................................................. 4 BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS ................................................................. 5 Hydraulic pump .......................................................................................................................................................... 5 Hydraulic swing motor ................................................................................................................................................ 5 Attachment cylinders .................................................................................................................................................. 5 VACUUM PUMP ............................................................................................................................................................. 6 Installation .................................................................................................................................................................. 6 Removal ..................................................................................................................................................................... 6 CLEANING THE HYDRAULIC SYSTEM ........................................................................................................................ 7 General ...................................................................................................................................................................... 7 Types of contamination .............................................................................................................................................. 7 Decontamination of the hydraulic system .................................................................................................................. 8
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-3
SPECIAL TOOLS
806128
CAS 10508 - Kit for unions 806127
CAS 10162A - Portable filter
CS99B532
CAS 30038 - Set of hydraulic flow and pressure test unions M1325
CAS 10193 - Kit for vacuum pump
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-4
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any operation on the hydraulic system, pressure in all the hydraulic circuits must first be at zero.
STEP 5
STEP 1 Place the machine on flat, level ground, with the attachment lowered to the ground, then shut down the engine.
STEP 2
Place the starter switch key (1) in the "OFF" position.
STEP 6
Place the starter switch key (1) in the "ON" position.
STEP 3
Press the button (1) located above the breather to release any remaining pressure.
Lower the function cancellation control arm (exit safety bar).
STEP 4
Operate the control levers ten times to right and left and backwards and forwards.
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-5
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS IMPORTANT: After having bled the air from the components, shut down the engine for five minutes and then check that no air bubbles appear in the hydraulic fluid reservoir.
Hydraulic swing motor
Hydraulic pump
CT07A010
CT07A037
Using a solvent, clean the upper surface of the pump and the air bleed plug. Remove the air bleed plugs. Fill the pump with hydraulic fluid via that orifice. Install and tighten the air bleed plugs. Start the engine, engine speed in idle mode. Loosen the pump air bleed plugs. Retighten the plugs as soon as the fluid flows without air bubbles from the ports. Clean carefully around the plugs
Lep SM4608000-0EN
Start the engine and run it at idle. Loosen the air bleed plug and make sure that hydraulic fluid flows out of that orifice. If necessary, shut down the engine and top up via that orifice. Install the plug, without tightening it, then start the engine and run it at idle. Let it run until hydraulic fluid flows out of the orifice. Completely retighten the air bleed plug. Perform at least two complete swings of the upperstructure, both to right and to left.
Attachment cylinders Start the engine and run it at idle. Extend and retract all the cylinder rods four or five times without bringing them against the stops, then do the same again three or four times, but this time bringing the cylinder rods against the stops.
Issued 09-07
Copyright © 8000-6
VACUUM PUMP Installation
Removal
STEP 1
STEP 1
Release pressure in the hydraulic system, see page 4.
Disconnect the vacuum pump harness from the batteries.
STEP 2
STEP 2 Disconnect the vacuum pump from the elbow union of the adaptor plate (B).
A
STEP 3 Remove the adaptor plate (B) from the hydraulic reservoir and scrap the O-ring.
STEP 4 Install a new O-ring on the hydraulic reservoir and install the plate (A). Remove the plate (A) on top of the hydraulic reservoir. NOTE: Do not remove the O-ring from the reservoir.
STEP 3 B
JD00019A
Install the adaptor plate (B) from the kit CAS 30028 on the hydraulic reservoir.
STEP 4
JD00020A
Connect the vacuum pump CAS 10193 to the elbow union of the adaptor plate. Connect the vacuum pump harness to the batteries.
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-7
CLEANING THE HYDRAULIC SYSTEM General
Types of contamination
Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components. Contamination manifests itself by the presence of foreign bodies in the hydraulic fluid. Contamination of the hydraulic system can occur in any of the following situations:
Contamination exists microscopic or visible.
1. When draining fluid or disconnecting a hydraulic line. 2. When disassembling a component. 3. Due to normal component wear. 4. Due to damaged or worn seals. 5. Due to a damaged component in the hydraulic system. All hydraulic systems can still operate even when slightly contaminated. Components of the hydraulic system are designed to withstand a slight degree of contamination. Any increase in the degree of contamination causes serious problems in the hydraulic system. Here is a non-exhaustive list of these problems: 1. Cylinder rod seals leak. 2. Control valve spools do not return to the neutral position.
basically
in
two
forms:
1. We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the hydraulic fluid. These particles are too small to be seen or felt. Microscopic contamination can be identified by the problems connected with microscopic contamination or by tests in the laboratory. Here are a few examples of the problems caused by microscopic contamination: A. Cylinder rod seals leak. B. Control valve spools do not return to the neutral position. C. The hydraulic system working temperature is high. D. Components wear quickly.
2. We speak of visible contamination when the presence of foreign bodies can be detected visually or by touch or smell. Visible contamination can cause a sudden failure of a component. Here are a few examples of problems caused by visible contamination: A. The fluid contains metal or other debris. B. The fluid contains air. C. The fluid is dark and thick.
3. Control valve spools are hard to move.
D. The fluid smells burnt.
4. Hydraulic fluid is too hot.
E. The fluid contains water.
5. Hydraulic components wear quickly. 6. Safety valves or non-return check valves do not close, due to contamination. 7. Repaired components soon fail again. 8. Cycles are slow; the machine does not have enough power. If one of the above situations occurs, it shows excessive contamination of the hydraulic system. To eliminate this contamination effectively, use the portable filter CAS 10162A.
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-8
Decontamination of the hydraulic system
STEP 7 2
STEP 1
1
Prepare the portable filter CAS 10162A as follows: 1. Eliminate all hydraulic fluid from the inlet and outlet hoses of the portable filter. 2. Remove the cartridge of the portable filter. 3. Eliminate all the hydraulic fluid from the portable filter. 4. Clean the interior of the cartridge housing. 5. Install a new filter cartridge.
CD00E178
STEP 2
Remove the bleed lever valve (1) under the hydraulic reservoir. Do not remove the adaptor (2).
Release pressure in the hydraulic system, see page 4.
STEP 8
STEP 3
Install the shut-off valve from the union kit CAS 10508 on the adaptor (2).
Drain the hydraulic fluid from the reservoir, see the operator’s manual.
NOTE: Make sure that the shut-off valve is closed.
NOTE: Do not assemble the access door under the hydraulic reservoir.
STEP 9
STEP 4
Fill the hydraulic reservoir with clean hydraulic fluid. See the Operator’s Manual.
Change the breather cartridge, the return filter and clean the inlet filter, see the operator’s manual.
STEP 10
NOTE: Do not install the plate complete with the breather.
STEP 5
Install the inlet hose from the portable filter on the shutoff valve under the hydraulic reservoir.
STEP 11
Change the pilot circuit filter, see the operator’s manual.
Install the long pipe from the union kit CAS 10508 on the portable filter return hose.
STEP 6
STEP 12
Change the Ultra Clean filter, see the operator’s manual.
Insert the long pipe in the hydraulic reservoir. Move the inlet filter long pipe as far away as possible.
STEP 13 Open the shut-off valve under the hydraulic reservoir.
Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-9
STEP 14
STEP 25
Install the portable filter on the upperstructure in such a manner that the machine can be operated. Attach the portable filter firmly to the machine.
Stop the portable filter and the engine.
STEP 15
Close the shut-off valve under the hydraulic reservoir.
Connect the electric cable from the portable filter to the batteries. Make sure that the electric cable is away from any moving components.
STEP 26 STEP 27 Remove the inlet pipe from the shut-off valve under the hydraulic reservoir.
STEP 16
STEP 28
Start the portable filter running.
Remove the long pipe from the hydraulic reservoir.
STEP 17
STEP 29
Start the engine, run it at half maximum speed for ten minutes. During those ten minutes, stir the hydraulic fluid in the hydraulic reservoir with the long pipe.
Disconnect the portable filter electric cable from the batteries and remove the portable filter from the machine.
STEP 18
STEP 30
Set engine speed to maximum and bring the hydraulic fluid up to its operating temperature by the following procedure:
Install a vacuum pump on the hydraulic reservoir. See page 6.
1. Operate the bucket and dipper controls in one direction (against the cylinder stops) for 30 seconds.
Start the vacuum pump.
STEP 31
2. Operate the bucket and dipper controls in the other direction (against the cylinder stops) for 30 seconds. 3. Repeat steps 1 and 2 until the hydraulic fluid temperature reaches 45 to 55°C (third bar on the hydraulic fluid temperature gauge on the illuminated instrument panel control screen).
STEP 19 With the engine at full speed; operate each cylinder (retract, extend) two times, one after another, for 45 minutes.
STEP 20 With the engine at full speed; operate the swing control several times 180° to the left and then to the right.
STEP 21 With the engine at full speed; position the attachment at right angles to the undercarriage. Use the attachment to raise the track off the ground. Operate the travel pedal, in one direction for two minutes and then in the other direction for two minutes. Repeat this cycle for ten minutes.
STEP 22 Repeat Step 21 for the other track.
STEP 23 Reduce the engine speed to idle.
STEP 24 Stir the hydraulic fluid in the hydraulic reservoir for 10 minutes with the long pipe. Lep SM4608000-0EN
Issued 09-07
Copyright © 8000-10
STEP 32 2 1
CD00E178
Remove the shut-off valve from the adaptor (2) and install the bleed lever valve (1). NOTE: Make sure that the bleed lever valve is closed.
STEP 33 Stop the vacuum pump and remove it from the hydraulic reservoir. See page 6.
STEP 34 Install the access panel under the hydraulic reservoir.
STEP 35 Change the return filter and clean the inlet filter. See the Operator’s Manual.
STEP 36 Change the pilot system filter. See the Operator’s Manual.
STEP 37 Change the Ultra-Clean filter, see the operator’s manual.
STEP 38 Check the level of the hydraulic fluid. Top up as necessary. See the Operator’s Manual.
Lep SM4608000-0EN
Issued 09-07
8001
Copyright ©
Section 8001 SPECIFICATIONS, TROUBLESHOOTING, INSPECTIONS AND HYDRAULIC PRESSURE SETTING
CNH
Lep SC4608001-0EN
Copyright © 2007 CNH France S.A. Printed in France March 2007
Copyright © 8001-2
TABLE OF CONTENTS
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 3 SPECIAL TOOLS ...................................................................................................................................................... 3 Tester .................................................................................................................................................................... 3 IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5 Pump..................................................................................................................................................................... 5 Control valve ......................................................................................................................................................... 6 6 solenoid valve row ............................................................................................................................................. 7 PREPARATION BEFORE INSPECTION.................................................................................................................. 8 Releasing pressure in the hydraulic system.......................................................................................................... 8 Main pressure measuring port .............................................................................................................................. 9 Installing the pilot pressure test point.................................................................................................................... 9 Flow curve........................................................................................................................................................... 10 Display on the "CHK1" monitor display ............................................................................................................... 11 Warming up the engine ....................................................................................................................................... 11 Warming up the hydraulic fluid............................................................................................................................ 11 CHECKING AND SETTING PROCEDURE ............................................................................................................ 12 Main pilot system relief (H).................................................................................................................................. 13 Checking the pilot accumulator ........................................................................................................................... 13 Main relief (A)...................................................................................................................................................... 13 Attachment control valve secondary reliefs......................................................................................................... 15 Swing port secondary relief................................................................................................................................. 16 Checking the pressure delivered by the proportional valve ................................................................................ 17 PROCEDURE FOR CHANGING OPERATION TYPE ............................................................................................ 18 ISO type .............................................................................................................................................................. 18 Old Sumitomo type ............................................................................................................................................. 18 Old Mitsubishi type.............................................................................................................................................. 19 Old Kobelco type................................................................................................................................................. 19
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-3
SPECIFICATIONS See section 1002.
SPECIAL TOOLS Tester 1 3
2
4
CD01B005
CP96E001
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
2. FEMALE COUPLING JOINT E47894 (1) PRESSURE TEST POINT 14X1.5 A3237549 (2) MALE COUPLING JOINT WITH UNION (3) AND PLUGS (4) CONTAINED IN THE SUITCASE CAS 30038
The Multi-Handy tester can be used every day in the workshop for normal operations. The Multi-Handy can be used for: Checking pressure (two pressure scales), maximum pressure, differential pressure (P delta), temperature, engine rpm and flow. 1 Multi-Handy 2051 tester .......................... D5444448 2 pressure detectors (0-600 bar)................ V5344460 2 straight unions for detector..................... W5344461 1 elbow union for detector .......................... X5344462 1 engine rpm detector ................................ Z5344463 3 cables (5 m long)..................................... E3144472 1 electric socket 220 V - 50 Hz .................. D5344467 1 cigarette lighter cable .............................. E5344468 1 instruction manual .................................... ------------1 carrying case........................................... N5344476
Lep SC4608001-0EN
CD98M009
3. 600 LITER FLOWMETER, ORDER THE FOLLOWING: ONE FLOWMETER RE3 Z5344486 TWO PLATES (M45X2) D4323359 TWO FLANGES (Ø 24) B8230183 FOUR HALF FLANGES D4024267 EIGHT SCREWS (12X75) Z1232983
Issued 03-07
Copyright © 8001-4
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES CAS XXXXX (INCLUDING TWO HIGH PRESSURE HOSES).
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-5
IDENTIFICATION OF HYDRAULIC COMPONENTS Pump Pi1
Dr
Psv
Pi2
a4 A3 Psv
a3
B1
Dr6 a1
a2 B3
A1
A2
CI02C509
Port
Description
Location
A1 - A2
Main pump output
SAE6000 psi 1"
B1
Main pump intake
SAE2000 psi 3"
Dr
Leak return
G 3/4 - 23
Proportional valve supply port
G 1/4 - 15
Negative pressure port
G 1/4 - 15
Psv Pi1 - Pi2
a1 - a2 - a3 - a4 Pressure test port
G 1/4 - 15
A3
Pilot pump output
G 1/2 - 19
B3
Pilot pump intake
G 3/4 - 20.5
Dr6
Pilot pump leak return
G 3/8 - 15
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-6
Control valve Ps2
Pa10
Pc5
Ps1
CI02C508
T3
T1 T2
Pc4
Pc1 DR1'
A5
A8
T5
B5
A4
Pc2 DR2'
B8
B4
A2
A7
B7
PA
A6
B6
PP
P3
PT
PH
B2 B1 P1
Pr1
Pr2 P2
A1 CI01N508
Port
Description
CI01N507
Port
Description
B8
Bucket opening
Ps1 - Ps2
Negative pressure
A8
Bucket closing
PT
Travel pilot pressure switch
B7
Boom lowering
PA
Attachment pilot pressure switch
A7
Boom raising
Pr1 - Pr2
Pressure text point P1 and P2
B6
RH front travel
PH
Main relief power boost control
A6
RH rear travel
PP
Pilot pressure
B5
Dipper out
DR1' - DR2'
A5
Dipper in
T3
Swing motor leak return
B2
LH swing
T5
Leak return to Ultra-clean filter
A2
RH swing
T6
To pilot cushion (pre-heating)
B4
Option circuit
Pc1
Dipper load holding
A4
Option circuit
Pc2
Boom load holding
B1
LH forward travel
Pc4
Priority to the swing (dipper)
A1
Load holding valve leak return
LH reverse travel
Pc5
Priority to boom raising
P1 - P2
Pump pressure
Pa10
By-pass 2nd flow on option
T1 - T2
Return to reservoir
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-7
6 solenoid valve row Y1
Y5
Y4
T
B
Y6
Y3
Y2
CD00E143
Port
Description
B
Pilot manifold supply
T
Return to reservoir
Y1
Swing pilot shut-off
Y2
Pilot pressure cancellation control
Y3
Swing brake control
Y4
Select travel 2nd speed
Y5
Power boost
Y6
Pilot cushion control cancellation
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-8
PREPARATION BEFORE INSPECTION
!
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction. Before pressurising the circuits, make sure that all the connections are correctly tightened and that the hoses and pipes are in good condition. Release pressure in the circuits completely before disconnecting pipes or carrying out any operation on the hydraulic system. Always use a small piece of cardboard or wood to detect leaks of fluid under pressure. Never use your hands.
!
WARNING: Any incorrect use or maintenance of a construction machine can cause accidents. Only persons who have read, understood and who observe the instructions in the operator's manual are accredited to use or maintain this machine.
!
WARNING: The accumulator of this machine is charged with nitrogen under pressure. In the event of incorrect operation of the circuit, change the accumulator. Never attempt to repair it. Non-observance of these instructions and the procedure shown below can cause serious or fatal injury.
Releasing pressure in the hydraulic system NOTE: Operation to be carried out before every service operation on the hydraulic system. 1. Position the machine on hard, flat ground.
7. Lower the pilot control cancellation lever. 8. Operate each control more than 10 times in both directions to release pressure in the circuits.
2. Open the bucket until the cylinder rod is completely retracted. 3. Extend the dipper until the cylinder rod is completely retracted. Lower the boom so that the end of the dipper is resting on the ground. Lower the tool to the ground. 4. Check with the diagnostic display in "S" mode that the following values are shown. CH K
CS00E544
MODE II S
ENG
1800
rpm
9. Press the button located on the hydraulic reservoir breather to release pressure in the reservoir.
1 P1
034.3
MPa
I
0405
mA
P2
034.3
MPa
WT
0080
°C
N
0.25
MPa
OT
0055
°C
Engine rpm
1800±10 rpm
Current
405 mA
5. Lower the engine speed to idle for 30 seconds, then shut down the engine. 6. Turn the starter key switch to "ON", without starting the engine.
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-9
Main pressure measuring port
B44
B42
330-1-05-00-29AA
A pressure sensor is mounted on the control valve and the circuit pressure can be displayed on the monitor (except for pilot pressure). B42, Pump pressure sensor P1. B44, Pump pressure sensor P2. Pressure on each relief valve (except for pilot pressure) can be confirmed on the monitor display.
Installing the pilot pressure test point
a3 (M3)
330.1.05.00.29EE
Install a pressure test point (M3) on the port (a3) of the pilot pump.
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-10
Flow curve Curve valid for a new pump
CI02C511
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-11
Display on the "CHK1" monitor display
N:
To access this screen: Select work mode H or S using control (2).
I:
Pump negative pressure in MPa (B43 pressure sensor).
ENG: Engine speed in rpm (B41 sensor). Pump control current value. Fan motor current value (when Travel Mode switch ON). WT:
Radiator coolant temperature. Hydraulic oil temperature.
OT:
Intake air temperature (only when Travel Mode switch ON).
Warming up the engine 1. Start the engine. The engine will have warmed up in 10-15 minutes.
1
2
2. Run the engine until the message "Auto warm up" disappears from the display monitor. CM00E001
Press simultaneously on the travel speed control (1) and on the work mode selector control (2) as shown above until the diagnostic screen CHK1 appears (3 seconds). CH K
MODE II H
ENG
2000
rpm
1
P1:
Warming up the hydraulic fluid 1. Display the "CHK1" monitor display. 2. Actuate the bucket and dipper controls in one direction (against the cylinder stops) for 30 seconds. 3. Actuate the bucket and dipper control in the other direction (against the cylinder stops) for 30 seconds.
P1
030.0
MPa
I
0300
mA
4. Repeat Steps 1 and 2 until hydraulic temperature reaches 45-55°C on display "CHK1".
P2
030.0
MPa
WT
0080
°C
5. Actuate the boom, swing and travel controls in both directions to warm up all the circuits to 45-55°C.
N
03.00
MPa
OT
0055
°C
P1 pump pressure in MPa
(Pressure B42 sensor)
Pressure checked
P2:
Boom raising Dipper retracting and extending LH and RH swing LH travel
P2 pump pressure in MPa
(Pressure B44 sensor)
Pressure checked
Lep SC4608001-0EN
Raising - lowering boom Dipper extending - retracting Bucket opening - closing RH travel
Issued 03-07
Copyright © 8001-12
CHECKING AND SETTING PROCEDURE Location of secondary relief valves E
D F G
B C A CI01N508 CI01N507
I
J
K
H
L
CI01N510 CI02C510
CS00M501
Tool used Look nut
Adjusting screw
Set pressure
Pressure for 1 turn of the screw (or for 1 shim*)
Main relief (standard pressure)
22 mm
19 mm
314 bar (31.4 MPa)
213 bar (21.3 MPa)
Main relief (power boost)
32 mm
26 mm
343 bar (34.3 MPa)
257 bar (25.7 MPa)
B
Boom raising port secondary relief
17 mm
Hexagon wrench 6 mm
363 bar (36.3 MPa)
212 bar (21.2 MPa)
C
Boom lowering port secondary relief
22 mm
Hexagon wrench 8 mm
245 bar (24.5 Mpa)
131 bar (13.1 MPa)
D
Dipper out port secondary relief
E
Dipper in port secondary relief
F
Bucket open port secondary relief
17 mm
Hexagon wrench 6 mm
363 bar (36.3 Mpa)
212 bar (21.2 MPa)
G
Bucket close port secondary relief
H
Pilot circuit main relief
24 mm
Hexagon wrench 6 mm
39 bar (3.9 MPa)
20 bar (2.0 MPa)
I
RH swing port secondary relief 41 mm
Hexagon wrench 14 mm
293 bar (29.3 MPa)
48 bar (4.8 MPa)
xx bar (xx MPa)
xx bar (xx MPa)
Item
A
Description
J
LH swing port secondary relief
K
Reverse travel secondary relief
L
Forward travel secondary relief
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-13
Main pilot system relief (H)
Main relief (A)
Test
Test
1. Connect a 0-100 bar pressure gauge to pressure test point P3.
1. Display the "CHK1" monitor display.
2. With the engine at full speed, select mode "S".
3. Operate and hold in position the dipper retracting control (against cylinder stops).
3. Move the pilot cancellation lever to its low position. 4. With the attachment, swing and travel controls in neutral, read the value on the pressure gauge: The value should be 39 to 41 bar (3.9 to 4.1 MPa).
Adjustment
2. With the engine at full speed, select mode "S".
4. Read the pressure on the monitor display:
2 1
1. Loosen the lock nut and turn the valve adjusting screw (H) until 39 to 41 bar (3.9 to 4.1 MPa) is reached. 2. Tighten the lock nut while holding the adjusting screw in position.
1
3. When the adjusting screw has been tightened, check the pressure again and make sure there are no leaks.
Checking the pilot accumulator 1. Raise the boom completely and extend the dipper. 2. Shut down the engine, with the starter key switch on "ON". 3. Operate the boom lowering or dipper retracting control several times consecutively. 4. The pressure in the accumulator should enable the boom lowering or dipper retracting function to be performed about six times.
APPROX. 2 SEC
8 SEC
1. Standard pressure 2. Power boost When the dipper cylinder is against the stops, the pressure is the standard value for 2 seconds, then at the valve over-setting for 8 seconds before falling back to standard pressure. Pump
Standard pressure
2-stage relief level
P1-P2
309 to 319 bar (30.9 to 31.9 MPa)
338 to 348 bar (33.8 to 34.8 MPa)
NOTE: To read the higher pressure - 2-stage relief level again, the control lever should be released, then operated against the cylinder stops.
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-14
Setting the power boost pressure
Adjusting the standard pressure NOTE: Carry out the procedure below only if the power boost pressure is correct, otherwise carry out the power boost pressure setting procedure.
2 1
3
4
4
330.1.05.00.29YA
1. Disconnect and plug the power boost pilot hose on the main relief.
3 330.1.05.00.29XA
2. Using a wrench, hold the adjusting screw (3) in position and loosen the lock nut (4).
1. Disconnect and plug the power boost pilot hose on the main relief.
3. Tight the adjusting screw (3) up to the stop.
2. Using a wrench, hold the adjusting screw (3) in position and loosen the lock nut (4).
4. Tighten the lock nut (4). 5. Start the engine and run it at maximum speed, select mode "S". 6. Operate and hold in position the dipper retracting control (against cylinder stops). 7. Loosen the lock nut (2) and turn the adjusting screw (1) until the power boost pressure is reached. NOTE: Tighten the screw (1) to increase the pressure. Loosen the screw (1) to reduce the pressure. 8. Using a wrench, hold the adjusting screw (1) and tighten the lock nut (2). 9. Check the pressure again. If the desired value is not obtained, repeat steps 6 to 9. 10. Cary out the standard pressure setting.
Lep SC4608001-0EN
3. Start the engine and run it at maximum speed, select mode "S". 4. Operate and hold in position the dipper retracting control (against cylinder stops). 5. Turn the adjusting screw (3) until the standard pressure is reached. NOTE: Tighten the screw (3) to increase the pressure. Loosen the screw (3) to reduce the pressure. 6. Using a wrench, hold the adjusting screw (3) in position and tighten the lock nut (4). 7. Check the pressure again. If the desired value is not obtained, repeat steps 2 to 6. 8. Stop the engine. 9. Reconnect the power boost pilot hose to the main relief.
Issued 03-07
Copyright © 8001-15
Attachment control valve secondary reliefs (B, C, D, E, F and G) NOTE: If the excavator is equipped with safety valves on the boom and the dipper, secondary reliefs (B) and (D) are not fitted or are overset. In this case it is necessary to set the pressures on the reliefs (B1-B2 and D1) mounted on the safety valves. NOTE: The attachment main reliefs are set to a higher pressure than the main relief valve. To check or set the attachment main reliefs, the main relief must be overset. NOTE: Since the pressure of the boom lowering valve is lower than the main relief, there is no need the overset the main relief (Steps 1 to 4 and 15 to 19).
Checking and setting the pressure 2
8. Read the pressure on the monitor display, the pressure should be: Boom raising
P1-P2
Boom lowering
P2
Dipper in
P1-P2
Dipper out
P1-P2
Bucket opening
P2
Bucket closing
P2
363±5 bar (36.3±0.5 MPa)
245±5 bar (24.5±0.5 MPa)
363±5 bar (36.3±0.5 MPa)
363±5 bar (36.3±0.5 MPa)
363±5 bar (36.3±0.5 MPa)
363±5 bar (36.3±0.5 MPa)
9. Carry out Steps 10 to 14 only if one of the attachment secondary reliefs has to have its pressure set. Otherwise go on to Step 15.
3 4
1 CS01K554 330.1.05.00.29YA
1. Disconnect and plug the power boost pilot hose on the main relief. 2. Using a wrench, hold the adjusting screw (1) in position and loosen the lock nut (2). 3. Tighten the adjusting screw (1) 180°. 4. Using a wrench, hold the adjusting screw (1) in position and tighten the lock nut (2). 5. Start the engine and run it at maximum speed, select mode "S". 6. Display the "CHK1" monitor display. 7. Operate and hold in position the corresponding attachment control (against the cylinder stops).
10. Using a wrench, hold the adjusting screw (4) of the secondary relief concerned in position and loosen the lock nut (3). 11. Operate and hold in position the corresponding attachment control (against the cylinder stops). 12. Turn the adjusting screw (4) of the secondary relief concerned until the correct pressure is obtained. 13. Using a wrench, hold the adjusting screw (4) in position and tighten the lock nut (3). 14. Check the pressure again. If the desired value is not obtained, repeat steps 10 to 14. 15. Using a wrench, hold the adjusting screw (1) of the main relief concerned in position and loosen the lock nut (2). 16. Operate and hold in position the dipper retracting control (against cylinder stops). 17. Turn the adjusting screw (1) until the correct standard pressure of the main relief concerned is obtained. NOTE: Tighten the screw (1) to increase the pressure. Loosen the screw (1) to reduce the pressure.
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-16 18. Using a wrench, hold the adjusting screw (1) in position and tighten the lock nut (2).
Adjustment
19. Check that the standard pressure of the main relief is correct, otherwise carry out Steps 15 to 19 again. 20. Stop the engine.
J
21. Reconnect the power boost pilot hose to the main relief.
I
22. If the value is not correct, loosen the lock nut (1) and turn the pressure setting screw (2) to adjust the pressure. Tighten to increase the pressure, untighten to decrease. When the pressure is correct, hold the screw (2) and tighten the lock nut (1). Reset the control valve main relief (A).
Swing port secondary relief (I, J)
CS99B596
(I) RH swing port secondary relief (J) LH swing port secondary relief
Test 1
2
330.1.05.00.29AD1 CD00E143
1. Carry out Steps 1 to 5 in "Checking".
1. Disconnect the connector (green) from the swing cancellation solenoid valve (Y1).
2. Using a wrench, hold the adjusting screw (2) and tighten the lock nut (1).
2. Display the "CHK1" monitor display.
3. Slowly operate the swing control lever to the right and gradually increase the engine speed to full speed to make sure that the swing is locked.
3. Start the engine and select mode "S". 4. Switch on the swing brake control on the instrument panel (indicator lamp ON). 5. Slowly operate the swing control lever to the right and gradually increase the engine speed to full speed to make sure that the swing is locked. 6. Repeat Step 5. for the LH swing, the pressures must be:
4. Turn the adjusting screw (2) until the standard pressure is reached. 5. Using a wrench, hold the adjusting screw (2) and tighten the lock nut (1). 6. Check the pressure again. If the desired value is not obtained, repeat steps 2 to 6.
Function RH swing
P1
293±4 bar
LH swing
P1
293±4 bar
Lep SC4608001-0EN
(29.3±0.4 MPa)
(29.3±0.4 MPa)
Issued 03-07
Copyright © 8001-17
Checking the pressure delivered by the proportional valve
Port a4(G 1/4)
KTJ10480-C01
1. Connect a pressure test point and a 0-100 bar pressure gauge to pump port G4. 2. Display the "CHK1" monitor display. 3. With the engine at full speed (no load engine), select mode "H" and then mode "S".
Secondary pressure (MPa)
Upper Limit
Upper Limit
Input current (mA) Controlled line graph 330.1.05.00.29R1
H mode
S mode
Pressure
12.9 bar (1.29 MPa)
20 bar (2.0 MPa)
Intensity
490 mA
405 mA
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-18
PROCEDURE FOR CHANGING OPERATION TYPE Select operation type by changing hoses located under the bulkhead joint behind the cab. After it has been changed, replace the instruction sticker for operation and take off ISO approved label.
ISO type
Old Sumitomo type
Adopted manufacturers: KATO, IHI, YUTANI, CAT, LBCE.
Adopted manufacturers: HITACHI.
Operation Levers
Operation Levers V1
SUMITOMO,
S1
V1
A1 A1 S1
A2
S2 B2
KOMATSU,
B1
B2
B1
A2 V2
V2
S2 CS00F530
Illustration of changing hoses
CS00F530S
Illustration of changing hoses A1: Arm out (move to S1)
A1: Arm out
A2: Arm in (move to S2)
A2: Arm in
B1: Bucket open
B1: Bucket open
B2: Bucket closed
B2: Bucket closed
V1: Boom down
V1: Boom down
V2: Boom up
V2: Boom up
S1: Swing left (move to A1)
S1: Swing left
S2: Swing right (move to A2)
S2: Swing right
000-8-02-01-07B 000-8-02-01-07B
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-19
Old Mitsubishi type
Old Kobelco type
Adopted manufacturers: MITSUBISHI, NIKO.
Adopted manufacturers: KOBELCO, FURUKAWA.
Operation Levers
Operation Levers
V1
V1
A2 S1
S1
S2
B2
B1
A1
S2
B2
B1
A2
A1 V2
V2 CS00F530M
Illustration of changing hoses
CS00F530K
Illustration of changing hoses A1: Arm out (move to V1)
A1: Arm out (move to V1)
A2: Arm in (move to V2)
A2: Arm in (move to V2)
B1: Bucket open (move to S2)
V1: Boom down (move to A2)
B2: Bucket closed (move to S1)
V2: Boom up (move to A1)
V1: Boom down (move to A1) V2: Boom up (move to A2) S1: Swing left (move to B1) S2: Swing right (move to B2)
B1: Bucket open (move to S2) B2: Bucket closed (move to S1) S1: Swing left (move to B1) S2: Swing right (move to B2)
000-8-02-01-07B
Lep SC4608001-0EN
Issued 03-07
Copyright © 8001-20
NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................
Lep SC4608001-0EN
Issued 03-07
8002
Copyright ©
Section 8002 REMOVAL AND INSTALLATION OF THE HYDRAULIC RESERVOIR
CNH
Lep SM4608002-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8002-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 HYDRAULIC RESERVOIR ............................................................................................................................................ 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 4 Description ................................................................................................................................................................. 6
SPECIFICATIONS See Section 1002.
Lep SM4608002-0EN
Issued 09-07
Copyright © 8002-3
HYDRAULIC RESERVOIR Removal NOTE: The numbers within brackets refer to the figures on pages 5 and 6.
STEP 1
STEP 8 Remove the screws (7) and the protective plate (8) on top of the control valve.
STEP 9 Loosen the screws (9) located under the machine. Open the side door on the right of the machine and remove the two screws (10). Remove the screw (10) located on the right of the fuel reservoir. Remove the protective plate of the reservoir (11).
STEP 10 Loosen the circlips (12) and disconnect the hose (13) under the hydraulic reservoir.
STEP 11 JS00163A1
Park the machine on hard, flat ground. Lower the attachment to the ground.
Attach identification tags to the output hoses. Disconnect the hoses.
STEP 2
STEP 12
Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
Remove the screws (14) and the retaining shims (15).
STEP 3 Attach a "DO NOT OPERATE" tag to the ignition key in the cab.
STEP 13 Using a hoist, remove the hydraulic reservoir (1) from the machine.
STEP 4 Remove the screws and the access panels under the hydraulic reservoir (1).
STEP 5 Using a container of suitable capacity, drain the hydraulic reservoir (1), by removing the plug (2).
STEP 6 Remove the screws (4) on top and inside the front boot, then remove the protective housing (3).
STEP 7 Remove the screws (5) and the protective plate (6) on top of the hydraulic reservoir (1).
Lep SM4608002-0EN
Issued 09-07
Copyright © 8002-4
Installation NOTE: The numbers within brackets refer to the figures on pages 5 and 6.
STEP 1 Using a hoist, position the hydraulic reservoir (1) on the machine.
STEP 2 Install the screws (14) and the retaining shims (15) to hold the hydraulic reservoir (1) to the machine undercarriage, tighten the screws to a torque, see the specifications. Install the drain plug (2).
STEP 3 Connect the hose (13) using the two circlips (12). Tighten the nut.
STEP 4 Connect the output hoses taking help of the tags installed during removal.
STEP 5 Install the reservoir protective plate (11) using screws (9) and (10).
STEP 6 Install the protective plate (6) under the hydraulic reservoir using retaining screws (5).
STEP 7 Install the protective plate (8) under the control valve using screws (7).
STEP 8 Install the protective housing (3) using screws (4), then install the screw mask inside the front boot.
STEP 9 Fill the hydraulic reservoir, see the section "Filling the reservoir" in the operator's manual and check for leaks.
STEP 10 Start the engine. Pressurise the hydraulic reservoir then stop the engine. Check again for leaks.
STEP 11 Install the protective plate under the machine using screws and flat washers.
Lep SM4608002-0EN
Issued 09-07
Copyright © 8002-5
Hydraulic reservoir
1
12 13
2
15
14
1 2 12
HYDRAULIC RESERVOIR PLUG CIRCLIP
Lep SM4608002-0EN
13 14 15
HOSE SCREW SHIM
Issued 09-07
Copyright © 8002-6
Description Location 3
4 4
8 10
7
11 10
9
7 6 5
3 4 5 6 7 8 9 10 11
PROTECTIVE HOUSING SCREW SCREW PROTECTIVE PLATE OF THE HYDRAULIC RESERVOIR SCREW PROTECTIVE PLATE OF THE CONTROL VALVE SCREW SCREW PROTECTIVE PLATE OF THE RESERVOIR
Lep SM4608002-0EN
Issued 09-07
Copyright ©
8003
Section 8003 REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC PUMP AND THE PILOT PUMP
CNH
Lep SM4608003-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8003-2
TABLE OF CONTENTS SPECIFICATIONS ........................................................................................................................................................ 3 SPECIAL TORQUE SETTINGS .................................................................................................................................... 3 MAIN HYDRAULIC PUMP ............................................................................................................................................ 4 Removal and installation ............................................................................................................................................ 4 PILOT PUMP ................................................................................................................................................................. 8 Removal and installation ............................................................................................................................................ 8 HYDRAULIC PUMP COUPLING .................................................................................................................................. 9 Cross-sectional view ................................................................................................................................................. 9 Removal and installation .......................................................................................................................................... 10
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-3
SPECIFICATIONS See Section 1002.
SPECIAL TORQUE SETTINGS Screw (7) for fixing the main pump to the coupling flange (5) ..............................367 to 496 Nm (270.68 to 365.83 lbf-ft) Screw (3) for fixing the coupling flange (5) to the engine ...........................................88 to 108 Nm (64.90 to 79.66 lbf-ft) Screw (6) for fixing the coupling (9) to the shaft of the hydraulic pump (8) .....................................295 Nm (217.58 lbf-ft) Screw (1) for fixing the coupling flange (2) to the engine flywheel ......................................................49 Nm (36.14 lbf-ft) Nuts for fixing the circlip of the silencer..................................................................68.7 to 98.1 Nm (50.67 to 72.35 lbf-ft) Silencer bracket fastening screw............................................................................68.3 to 76.3 Nm (50.37 to 56.28 lbf-ft)
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-4
MAIN HYDRAULIC PUMP Removal and installation
STEP 4
STEP 1
JS00163A1
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
1
STEP 3
Remove the access panel (1) below the hydraulic reservoir.
STEP 5 Put an appropriate container under the hydraulic reservoir. Open the drain cock and drain the hydraulic fluid. Close the cock.
Disconnect the battery ground (-) cable (1) from the battery.
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-5
STEP 6
STEP 8 A 1 B
2
CD02H004
Remove all the retaining screws (A) from the panel (B), then remove the panel (B).
STEP 9
Remove the engine hood (1) then the protective grille (2).
1
STEP 7 CD00F108
B
Remove the circlip (1) fastening the silencer pipe to the turbocharger. NOTE: All the engine and the exhaust system to cool down before starting any disassembly.
A CD02C147
Disconnect all the hoses from the quick coupling control block (A). Remove the block (A) from the panel (B).
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-6
STEP 10
STEP 13
1
CD00F110
Remove the four retaining nuts from the silencer circlips, then remove the two circlips. NOTE: When installing, tighten the nuts to the torque specified on page 3.
STEP 11
CD02H004
To facilitate proper installation, attach identification tags to all hoses and electrical connections of the main hydraulic pump and the pilot pump.
STEP 14 Remove the pipes, the hydraulic hoses and the electrical connections. Seal all hoses and unions of the main pump as well as those of the pilot pump.
STEP 15 Install an appropriate lifting apparatus on the hydraulic pump. Do not leave any slack so that the pump can be supported once the fastening screws of the pump are removed.
STEP 16 1
Remove the retaining screws of the hydraulic pump.
CD00F111
Remove the silencer assembly (1) from the machine.
STEP 12
NOTE: When installing, tighten the screws to the torque specified on page 3.
STEP 17 Remove the hydraulic pump from the motor and put it away from the machine. Place the hydraulic pump on a clean workbench using suitable brackets. NOTE: Carry out the following step only if a new hydraulic pump needs to be installed.
1
STEP 18 Remove the connections of the hydraulic pump that has just been removed and install them on the new hydraulic pump. Remove and install the connections one after another to avoid improper installation of the connections on the new hydraulic pump. CD00F076
Remove the three retaining screws (1) from the silencer bracket, then remove the silencer bracket.
NOTE: For installing the hydraulic pump, proceed in the reverse order to that of removal. Replace all rings with new rings.
NOTE: When installing, tighten the screws to the torque specified on page 3.
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-7
STEP 19
NOTE: Before carrying out any work with the machine, operate the swing, travel and the attachment for five minutes with the engine at idle speed. Check that there are no leaks in the system, check the oil level in the hydraulic reservoir. Top up if necessary, refer to Section 8001.
2
1
CD00E176
Remove the four screws and washers (1). Remove the cover (2) and the O-ring from on top of the hydraulic reservoir. Scrap the O-ring. Fill the hydraulic reservoir with hydraulic fluid (see Section 1002) up to a level in between the "high" and "low" marks on the visual gauge. Install the cover with a new O-ring, fasten it using four screws and washers (1).
Connect the ground (-) cable (1) of the battery.
STEP 20 NOTE: Always drain the air out from the hydraulic pump before starting the engine. If the air has not been drained out, the pump can get damaged. For the procedure, see Section 8000.
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-8
PILOT PUMP Removal and installation
STEP 5
STEP 1
NOTE: When installing, proceed in the reverse order to that of removal. Replace the O-rings with new O-rings. Bleed the hydraulic pump.
Refer to "Removal of the hydraulic pump" in this section and carry out Steps 1 to 3.
STEP 2 To prevent any fluid leaks when disconnecting hydraulic hoses, connect a vacuum pump to the hydraulic reservoir (see Section 8000). Start the vacuum pump.
STEP 3
NOTE: Stop the vacuum pump. NOTE: Before carrying out any work with the machine, operate the swing, travel and the attachment for five minutes with the engine at idle speed. Check that there are no leaks in the system, check the level of oil in the hydraulic reservoir, top up if necessary. Adjust the hydraulic pump, refer to Section 8001.
2 1
4 3
CD02H004
Place an appropriate container under the pilot pump (1) to recover the hydraulic fluid that could escape from one of the disconnected hoses or from the hydraulic pump when the pilot pump (1) has been removed. Disconnect the hoses (2), (3) and (4). Plug the union and the hoses.
STEP 4 Remove the pilot pump retaining screws and remove the pilot pump.
Lep SM4608003-0EN
Issued 09-07
Copyright © 8003-9
HYDRAULIC PUMP COUPLING Cross-sectional view
A 9
2 6
1
8
5
7 5 3 4 CS02H583
1 2 3 4 5
SCREW COUPLING FLANGE SCREW WASHER PUMP FLANGE
Lep SM4608003-0EN
6 7 8 9
HUB RETAINING SCREWS SCREW HYDRAULIC PUMP COUPLING HUB
Issued 09-07
Copyright © 8003-10
Removal and installation NOTE: The numbers within brackets refer to the schematic on page 9.
STEP 1 Remove the screws (3) and the washers (4) from the coupling flange (5). Remove the assembly from the hydraulic pump.
STEP 2 Remove the retaining screws (6) from the splined hub (9), then remove the hub.
2
5
6
CS02H584
STEP 3 Disassemble the screws (1) from the coupling flange (2) and remove the flange. Visually check the condition of the coupling splines. Change them if necessary.
STEP 4 Remove the screws (7) and the coupling flange (5) from the hydraulic pump (8). NOTE: When installing the hydraulic pump coupling, proceed in the reverse order to that of removal. Adjust the position of the coupling by aligning the splined hub (9) with the end of the pump shaft (arrows) corresponding to the stop on the pump shaft. Assemble and tighten the splined hub retaining screw (6).
Lep SM4608003-0EN
Issued 09-07
Copyright ©
Section
REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC CONTROL VALVE
CNH
Lep SM4608004-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8004
8004
Copyright © 8004-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS..................................................................................................................................... 2 MAIN CONTROL VALVE ............................................................................................................................................... 3 Removal and installation ............................................................................................................................................ 3
SPECIFICATIONS Weight of control valve .......................................................................................................................... See Section 1002 Adjusting the valves............................................................................................................................... See Section 8001
SPECIAL TORQUE SETTINGS Control valve mounting on upperstructure frame ................................................ 333 to 392 Nm (245.61 to 289.12 lbf-ft)
Lep SM4608004-0EN
Issued 09-07
Copyright © 8004-3
MAIN CONTROL VALVE Removal and installation
STEP 5
STEP 1
JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2
Remove the upper access panel retaining screws and remove the panels.
Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
NOTE: When installing, tighten the screws to torque (see special torque settings on page 2) (apply Loctite 262 on the threads).
STEP 3
STEP 6 Start the vacuum pump.
STEP 7 Attach identification tags to all hoses, pipes and electrical wires of the control valve. Disconnect and seal the hoses and pipes. Seal the control valve unions. Disconnect the electrical connections.
STEP 8 Stop the vacuum pump.
STEP 9 Disconnect the earth (-) cable (1) from the battery.
STEP 4 To prevent any fluid leaks when disconnecting hydraulic lines, connect a vacuum pump to the hydraulic reservoir (see Section 8000).
Install lifting rings in the threaded orifices on the top of the control valve.
Lep SM4608004-0EN
Issued 09-07
Copyright © 8004-4
STEP 10
NOTE: The following step is to be performed only if the control valve has to be changed.
STEP 13 Remove the unions and manifolds from the control valve which has just been removed and mount them on the new control valve. Remove and install the unions and manifolds one after another to make sure that they are correctly installed on the new control valve. NOTE: When installing, follow the same procedure in the reverse order. Replace all seals with new seals. NOTE: Before carrying out any work with the machine, operate the swing, travel and the attachment for five minutes with the engine at idle speed. Check that there are no leaks in the system, check the level of oil in the hydraulic reservoir, top up if necessary. Adjust the valves in the control valve (see Section 8001).
Install a lifting device on the control valve rings.
STEP 11
1
CS02J502
Remove the retaining screws (1) and washers from the control valve. NOTE: When installing, tighten the screws to torque (see special tightening torques on page 2).
STEP 12
Carefully raise and guide the control valve out of the upperstructure frame. Move all the hoses and pipes out of the way. Remove the control valve from the machine and place it on suitable stands.
Lep SM4608004-0EN
Issued 09-07
Copyright ©
Section 8005
OF THE ATTACHMENT CYLINDERS
CNH
Lep SM4608005-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8005
REMOVAL AND INSTALLATION
Copyright © 8005-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 PREPARATION BEFORE REMOVAL/INSTALLATION.................................................................................................. 2 BOOM CYLINDER .......................................................................................................................................................... 3 Description ................................................................................................................................................................. 3 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 6 DIPPER CYLINDER........................................................................................................................................................ 8 Description ................................................................................................................................................................. 8 Removal ..................................................................................................................................................................... 9 Installation ................................................................................................................................................................ 11 BUCKET CYLINDER..................................................................................................................................................... 14 Description ............................................................................................................................................................... 14 Removal ................................................................................................................................................................... 15 Installation ................................................................................................................................................................ 17
SPECIFICATIONS See Section 1002.
PREPARATION BEFORE REMOVAL/INSTALLATION - Park the machine on hard, flat ground. - Completely retract the bucket and dipper cylinder rods and lower the attachment to the ground. - Release pressure in the hydraulic circuit and install a vacuum pump on the hydraulic reservoir (see Section 8000).
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-3
BOOM CYLINDER Description
4 2 4
6 3
5
4 1 8
4
7 5
7
6 3
8 9
2 1
CS02B563
1 2 3 4 5
NUT SCREW LOCKING BUSHING SHIM WASHER
Lep SM4608005-0EN
6 7 8 9
SCREW SHAFT BOOM CYLINDER SHAFT
Issued 09-07
Copyright © 8005-4
Removal
STEP 3
NOTE: The numbers within brackets in the following steps refer to the boom cylinder schematic on page 3.
2
9
2
STEP 1 4
A
3 1 1
JS00579A
JS00577A
Disconnect the lubrication hose (A) from the boom cylinder.
Remove the nuts (1) and the screws (2). Remove the screws from the shaft (9) and the locking rings (3). Push the shaft far enough so that it does not intefere with the removal of the boom cylinder. Remove the shims (4) and the locking rings.
STEP 4
NOTE: Lift the cylinder carefully, the cylinder is heavy, its weight has to be balanced with slings during lifting.
STEP 2
A
JS00580A
Install a support (A) in front of the boom cylinder. Lower the front of the boom cylinder on the support. JS00578A
STEP 5
Attach a suitable lifting device to the boom cylinder. Use the total movement to get sufficient support during removal of the boom cylinder.
B
JS00581A
Attach a sling (B) to hold the cylinder rod to the cylinder barrel.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-5
STEP 6
STEP 10
Start the vacuum pump.
Repeat steps 1 to 9 to remove the other cylinder.
STEP 7
A
Disconnect the hydraulic supply hoses (A) from the boom cylinder.
STEP 8 Plug the hoses with plugs and the unions with caps. Stop the vacuum pump.
STEP 9
6 5 7 B A
Remove the screw (6) and the washer (5). Remove the shaft (7), using a steel bar and hammer.
Carefully lift the boom cylinder and move it away from the machine. Place the boom cylinder on suitable supports. Remove the sling that holds the cylinder rod to the cylinder barrel.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-6
Installation
STEP 3
STEP 1
6 5 7
B B
A
JS00586A
Attach a suitable sling (B) to the boom cylinder to hold the cylinder rod to the cylinder barrel. NOTE: Lift the cylinder carefully. The cylinder is heavy, its weight has to be balanced with slings during lifting.
Install the shaft (7) using washers (5) and screws (6). Using a strip thickness gauge, check that there is a clearance of 1 to 3.5 mm (0.05 to 0.11 in) between the mounting bracket and the mounting ring of the cylinder barrel. If necessary, remove the screw, the shaft and add one or more shim(s) as required in order to get the correct clearance. Install the pin and the screw.
STEP 2
A
Using a suitable lifting device, lift the boom cylinder. Align the boom cylinder with the mounting brackets of the frame. Place a suitable support under the boom cylinder to support it.
A
Start the vacuum pump. Remove the plugs from the hydraulic hoses (A) and the caps from the unions. Connect the two hydraulic supply hoses on the boom cylinder.
STEP 4
JS00590A
Lift the boom cylinder and align the rod end of the cylinder with the mounting ports of the boom.
STEP 5 Repeat steps 1 to 6 to install the second boom cylinder.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-7
STEP 6
STEP 8 A
9 Install the pin (9) and the shims (4).
JS00656A
Connect the lubrication hose (A) to the boom cylinders.
STEP 7
STEP 9 2
Remove the vacuum pump and bleed the air from the boom cylinders (see Section 8000).
STEP 10 Check the hydraulic fluid level in the reservoir. Top up as required.
3
STEP 11 Lubricate the linkages.
1
JS00592A
Install the locking bushings (3). Install the screws (2) through the locking rings and the shaft. Using a set of spacer rings, check that there is a clearance of 1 to 3.5 mm (0.05 to 0.11 in) between the mounting bracket and the mounting ring of the cylinder rod. If necessary, remove the screws and the pin and add or remove one or more shim (s) as required to obtain the correct clearance. Install the pin and the screws. Install the first nut (1) on the screw and tighten until the nut touches the locking ring. Unscrew the nut by a quarter of a turn and, using two wrenches, install the second nut (1) to lock the first nut in position. Remove the sling from the boom cylinder.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-8
DIPPER CYLINDER Description
8
7
6
5
4
3
2 1
CS02B564
1 2 3 4
SCREW WASHER PIN SCREW
Lep SM4608005-0EN
5 6 7 8
WASHER PIN DIPPER CYLINDER SHIM
Issued 09-07
Copyright © 8005-9
Removal
STEP 4
NOTE: The numbers within brackets in the following steps refer to the dipper cylinder schematic on page 8.
STEP 1 B
A
JS00586A
8
Attach a suitable sling (B) to hold the cylinder rod to the cylinder barrel.
Place a wooden shim (A) under the dipper cylinder (8).
STEP 2
1 2
Remove the screw (1) and the washer (2).
STEP 3
3
Remove the shaft (3) using a steel bar and hammer.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-10
STEP 5
STEP 10
Start the vacuum pump.
STEP 6
6 5 A 4 Remove the screw (4) and the washer (5). Remove the shaft (6), using a steel bar and hammer. Disconnect the two hydraulic supply hoses (A) from the dipper cylinder.
STEP 7 Plug the hydraulic hoses with plugs and the unions with caps. Stop the vacuum pump.
STEP 8
A
JS00599A
Disconnect the lubrication hose (A) from the dipper cylinder. NOTE: Lift the cylinder carefully, the cylinder is heavy, its weight has to be balanced with slings during lifting.
STEP 9
Attach a suitable lifting device to the dipper cylinder. Use the total movement to get sufficient support during removal of the dipper cylinder. Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-11
Installation
STEP 11 8
STEP 1
B
JS00602A
Carefully lift the dipper cylinder and move it away from the dipper. Remove the shims (8). Place the dipper cylinder on suitable supports.
STEP 12
JS00586A
Attach a suitable sling (B) to the dipper cylinder to hold the cylinder rod to the cylinder barrel. NOTE: Lift the cylinder carefully, the cylinder is heavy, its weight has to be balanced with slings during lifting.
STEP 2 8 B
JS00586A
Remove the sling (B) that holds the cylinder rod to the cylinder barrel. JS00602A
Attach a suitable lifting device to the dipper cylinder, lift the dipper cylinder and bring it in position. Align the dipper cylinder mounting ports with the boom brackets and install the shims (8).
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-12
STEP 3
STEP 5
A
6 5 4 CS02B567
Install the shaft (6) using washers (5) and screws (4). Using a set of spacer rings, check that there is a clearance of 1 to 3 mm (0.03 to 0.11 in) between the mounting bracket and the mounting ring of the cylinder barrel. If necessary, remove the screw, the shaft and add or remove one or more shim(s) (8) as required in order to get the correct clearance. Install the pin and the screw.
Start the vacuum pump. Remove the plugs from the hydraulic hoses (A) and the caps from the unions. Connect the hydraulic supply hoses on the dipper cylinder.
STEP 6
STEP 4
B
A
JS00586A
Remove the sling (B) that holds the cylinder rod to the cylinder barrel.
STEP 7 JS00604A
Connect the lubrication hose (A) to the dipper cylinder.
JS00606A
Align the dipper cylinder mounting ports with the dipper ports.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-13
STEP 8
3 2 1
CS02B566
Install the shaft (3), the washer (2) and the screw (1). Using a set of spacer rings, check that there is a clearance of 4.5 to 5.5 mm (017 to 0.21 in) between the mounting bracket and the mounting ring of the cylinder rod. If necessary, remove the screw and the shaft and add one or more shim(s) as required in order to get the correct clearance. Install the pin and the screw.
STEP 9 Remove the vacuum pump and bleed the air from the dipper cylinder (see Section 8000).
STEP 10 Check the hydraulic fluid level in the reservoir. Top up as required.
STEP 11 Lubricate the linkages.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-14
BUCKET CYLINDER Description 4 3
11 6
12
6 9 7
7
9 4
6
5
4
5
13 9 7
2
1 8
12 6
9 10
13 5
10
4
2 1
2
1
1 3
2
CRPH06C012G
1 2 3 4 5 6
NUT SCREW SHAFT SHIM BUSHING O-RING
Lep SM4608005-0EN
7 8 9 10 11 12 13
NIPPLE LINK SEAL O-RING BUCKET CYLINDER COMPENSATOR O-RING
Issued 09-07
Copyright © 8005-15
Removal
STEP 2
NOTE: The numbers within brackets in the following steps refer to the bucket cylinder diagram on page 14.
2 1
STEP 1
A 12
JS00609A
Remove the nuts (1) from the screw (2) and remove the screw from the compensator (12).
11
STEP 3 Place a wooden cylinder (11).
shim
(A)
under
the
bucket
3
NOTE: Lift the cylinder carefully, the cylinder is heavy, its weight has to be balanced with slings during lifting.
Remove the shaft (3), using a steel bar and hammer.
STEP 4
B
Attach a suitable sling (B) to the bucket cylinder to hold the cylinder rod to the cylinder barrel.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-16
STEP 5
STEP 8
A C A
A
Start the vacuum pump. Disconnect the two hydraulic hoses (A) from the bucket cylinder. Plug the hydraulic hoses with plugs and the unions with caps. Stop the vacuum pump.
B Remove the screw (A) and the washer (B). Remove the shaft (C) from the dipper.
STEP 9 A
STEP 6
B
JS00614A
Remove the grease hose. NOTE: Remove the wooden shim when the bucket cylinder is raised.
Carefully lift the bucket cylinder and move it away from the dipper. Remove the shims (A). Place the bucket cylinder on suitable supports.
STEP 10
STEP 7 B
JS00586A
Lift bucket cylinder, using a sling.
Lep SM4608005-0EN
Remove the sling (B) that holds the cylinder rod to the cylinder barrel.
Issued 09-07
Copyright © 8005-17
Installation
STEP 4
STEP 1
B
B
B
JS00586A
Attach a suitable sling (B) to the bucket cylinder to hold the cylinder rod to the cylinder barrel. NOTE: Lift the cylinder carefully, the cylinder is heavy, its weight has to be balanced with slings during lifting.
Start the vacuum pump. Remove the plugs from the hydraulic hoses (B) and the caps from the unions. Connect the hydraulic hoses to the unions of the bucket cylinder. Stop the vacuum pump.
STEP 5
STEP 2
Install the grease hose to the bucket cylinder.
STEP 6 Install the bucket cylinder on the dipper.
STEP 3 B
A
C B
JS00586A
Remove the sling (B) that holds the cylinder rod to the cylinder barrel.
With the cylinder and the shims in position, install the shaft (C), the screw (A) and the washer (B). Using a set of spacer rings, check that there is a clearance of 1 to 3 mm (0.039 to 0.11 in) between the mounting bracket and the mounting ring of the cylinder barrel. If necessary, remove the screw, the shaft and add or remove one or more shim as required in order to get the correct clearance. Install the pin and the screw.
Lep SM4608005-0EN
Issued 09-07
Copyright © 8005-18
STEP 7 11
12
Lift the bucket cylinder (11) to align the cylinder rod and the compensators (12). Install the shims.
STEP 8 2 3
1
Install the pin (3) and the screw (2). Using a set of spacer rings, check that there is a clearance of 1.5 to 2.5 mm (0.059 to 0.098 in) between the connecting rod and the mounting ring of the cylinder rod. If necessary, remove the screw and the shaft and add or remove one or more shim(s) as required in order to get the correct clearance. Install the pin and the screw. Install the first nut (1) on the screw and tighten until the nut touches the boss. Unscrew the nut by a quarter of a turn and, using two wrenches, install the second nut (1) to lock the first nut in position.
STEP 9 Remove the vacuum pump and bleed the air from the bucket cylinder (see Section 8000).
STEP 10 Check the hydraulic fluid level in the reservoir. Top up as required.
STEP 11 Lubricate the linkages.
Lep SM4608005-0EN
Issued 09-07
Copyright ©
Section 8006 REMOVAL AND INSTALLATION
8006
OF THE HYDRAULIC SWIVEL
CNH
Lep SM4608006-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8006-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS...................................................................................................................................... 2 HYDRAULIC SWIVEL ..................................................................................................................................................... 3 Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS Weight ................................................................................................................................................... See Section 1002
SPECIAL TORQUE SETTINGS Capscrews for retaining locking bar ...................................................................................................... See Section 1002 Capscrews for retaining hydraulic swivel outer sleeve on upperstructure ............................................. See Section 1002
Lep SM4608006-0EN
Issued 09-07
Copyright © 8006-3
HYDRAULIC SWIVEL Removal and installation
STEP 5
STEP 1
2 JS00163A1
Park the machine on flat, hard ground. Lower the attachment to the floor.
STEP 2
1 CI00F500
Release pressure in the hydraulic system and release pressure in the hydraulic reservoir (see Section 8000).
Remove the retaining hardware (1) from the lower plates (2) then remove the plates.
STEP 3
1
CT07A009
Disconnect the earth cable (1) from the battery.
STEP 4 To prevent any fluid loss when disconnecting hydraulic lines, connect a vacuum pump to the reservoir (see Section 8000).
Lep SM4608006-0EN
Issued 09-07
Copyright © 8006-4
STEP 6
STEP 11 1 3 2
CS02C504
CD02C137
To facilitate installation, attach identification labels to all the hydraulic swivel hoses (outer and inner).
STEP 7
Remove the retaining screws (1), the locking bar (2) and the retaining screws (3) from the hydraulic swivel outer component.
Start the vacuum pump.
NOTE: When installing, tighten to the torque specified in Section 1002.
STEP 8
STEP 12 Raise the hydraulic swivel sufficiently to free it from its bracket, so that it can be pivoted 90°. Place the hydraulic swivel on the ground. NOTE: When installing, use the same procedure in the reverse order. Replace all O-rings with new O-rings. Before operating the machine, operate the travel, stop the engine and check that there are no leaks. If there is a leak, tighten the hose connections, check the level of hydraulic oil in the reservoir and top up if necessary.
CS02C503
Disconnect the hoses from the hydraulic swivel. Plug the hydraulic swivel hoses and orifices.
STEP 9 Stop the vacuum pump.
STEP 10 Connect suitable lifting equipment to the hydraulic swivel. Do not leave any slack since the hydraulic swivel has to be supported once the retaining screws are removed.
Lep SM4608006-0EN
Issued 09-07
Copyright ©
Section 8007
8007
REMOVAL AND INSTALLATION OF THE PILOT FUNCTION BLOCKS
CNH
Lep SM4608007-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8007-2
TABLE OF CONTENTS SPECIAL TORQUE SETTINGS .................................................................................................................................... 2 PILOT FUNCTION BLOCKS ......................................................................................................................................... 3 Travel pedal block ..................................................................................................................................................... 3 LH control lever ......................................................................................................................................................... 4 RH control lever ........................................................................................................................................................ 8 Swing shuttle block ................................................................................................................................................. 11 Cushion control valve .............................................................................................................................................. 12 Servo control and return manifold block .................................................................................................................. 12 6 solenoid valve block ............................................................................................................................................. 13
SPECIAL TORQUE SETTINGS Control lever block lever locknut ......................................................................................................... 41 Nm (30.24 lbf-ft)
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-3
PILOT FUNCTION BLOCKS Travel pedal block
STEP 5
Removal and installation
Attach identification tags on all hoses of the control pedal block.
STEP 1
STEP 6 Start the vacuum pump.
STEP 7 Provide for a container to recover any possible hydraulic fluid leaks.
STEP 8
JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
1
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 3
2
Disconnect the battery ground (-) cable (1) from the battery.
STEP 4 To prevent any fluid leaks when disconnecting hydraulic lines, connect a vacuum pump to the hydraulic reservoir (see Section 8000).
Remove and seal the hydraulic hoses (1). Remove the junction joints (2), put plugs on the ports of the control pedal, then discard the O-rings. NOTE: When installing, replace all O-rings with new Orings.
STEP 9 Stop the vacuum pump.
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-4
LH control lever
STEP 10
Removal and installation 1
NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1 4 5 3
2 6 CD00G047
Remove the screws (1), then remove the lever (4). Remove the screws (2), then remove the pedal (5). Remove the screws (3), then remove the bracket (6). Proceed in the same manner for the second pedal. CD00G048
STEP 11
Lift the boot. Loosen and remove the four retaining screws from the front upper portion of the control arm.
STEP 2
2 1 CD00E046
1
CD00G049
Loosen and remove the retaining screw (1) from the function cancellation lever (2), then remove the lever.
Put the floor carpet away from the pedals. Remove the screws (1) that fasten the control pedal block to the cab floor, then remove the control pedal block. NOTE: When installing, proceed in the reverse order to that of removal. Start the engine and operate the control levers. Stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-5
STEP 3
STEP 6
CD00G050
Loosen and remove the three retaining screws from the inner cab access bar, then remove the access bar.
STEP 4
CD00G053
Loosen and remove the retaining screws from the arm angle adjustment and function cancellation lever, then remove the lever.
STEP 7
1
2
CD00G051
Label and disconnect the electrical connections (1), remove the compartment control casing assembly (2).
STEP 5
CD00G054
Lift the upper portion of the control arm, label and disconnect the electrical connections.
STEP 8
CD00G052
Loosen and remove the four retaining screws from the rear upper portion of the control arm.
CD00G055
Loosen the locknut, unscrew the control lever and remove the upper portion of the control arm. NOTE: When installing, tighten the lock nut to torque (see special torque settings on page 2).
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-6
STEP 9
STEP 11 4 3
5 2
6
2 1 JD00764A
1 2 3 4 5 6
CD00G057
Loosen and remove the retaining screws from the lefthand side of the control arm.
CLIP NUT HANDLE GROMMET CONNECTOR LEVER
STEP 12
Cut the clip (1) and discard it. Loosen the nut (2). Unscrew and remove the handle (3) and the connector (5) from the lever (6). Remove the nut (2) to remove the grommet (4). NOTE: Replace the grommet if it is damaged. The grommet protects the unions from all types of contamination.
1
STEP 10
CD00G058
Remove from the safety bar side, the rod (1) that links the function cancellation lever to the safety bar.
STEP 13
1 CD00G056
Loosen and remove the upper retaining screws and the two lower retaining screws from the front portion of the control arm.
CD00G059
Loosen and remove the retaining screws from the plate (1).
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-7
STEP 14
STEP 18
2 2 1 1
CD00G060
Loosen and remove the screws that fasten the retaining plate of the control lever (1) to the bracket (2).
STEP 15
CD00G062
Attach identification tags to all hoses of the control lever block. Remove and seal the hydraulic hoses. Remove the junction unions, put plugs on the ports of the control lever block, then discard the O-rings. Loosen and remove the retaining screws (1) from the plate (2). NOTE: When installing, replace all O-rings with new Orings.
STEP 19 Stop the vacuum pump.
2
NOTE: When installing, proceed in the reverse order to that of removal. Start the engine and operate the control levers. Stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
1
CD00G061
Take the control lever block (1) out from the bracket (2).
STEP 16 Start the vacuum pump.
STEP 17 Provide for a container to recover any possible hydraulic fluid leaks.
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-8
RH control lever
STEP 3
Removal and installation NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1 1
CD00G068
Loosen and remove the retaining screws from the arm angle adjustment lever.
STEP 4 CD00G065
CD00G069
CD00G066
Remove the trim panel (1) then remove the retaining screws from the air-conditioning control box.
Lift the boot. Loosen and remove the retaining screws from the front upper portion of the control arm.
STEP 5
STEP 2
1
2
CD00G070
CD00G067
Label and disconnect the electrical connection (1) then remove the air-conditioning control box (2).
Lep SM4608007-0EN
Loosen and remove the retaining screws from the rear upper portion of the control arm.
Issued 09-07
Copyright © 8007-9
STEP 6
STEP 8 4 3
5 2 CD00G071
Lift the upper portion of the control arm, label and disconnect the electrical connections.
STEP 7
6
2 1 JD00764A
1 2 3 4 5 6
CLIP NUT HANDLE GROMMET CONNECTOR LEVER
Cut the clip (1) and discard it. Loosen the nut (2). Unscrew and remove the handle (3) and the connector (5) from the lever (6). Remove the nut (2) to remove the grommet (4). NOTE: Replace the grommet if it is damaged. The grommet protects the unions from all types of contamination.
STEP 9 CD00G072
Loosen the locknut, unscrew the control lever and remove the upper portion of the control arm. NOTE: When installing, tighten the lock nut to torque (see special torque settings on page 2).
CD00G073
Loosen and remove the upper retaining screws and the lower retaining screws from the front portion of the control arm.
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-10
STEP 10
STEP 13 Start the vacuum pump.
STEP 14 Provide for a container to recover any possible hydraulic fluid leaks.
STEP 15
1
2
CD00G074
Loosen and remove the retaining screws from the plate (1).
STEP 11 1
1
CD00G077
Attach identification tags to all hoses of the control lever block. Remove and seal the hydraulic hoses. Remove the junction unions, put plugs on the ports of the control lever block, then discard the O-rings. Loosen and remove the retaining screws (1) from the plate (2). NOTE: When installing, replace all O-rings with new Orings.
2
STEP 16 CD00G075
Loosen and remove the screws that fasten the control valve (1) retaining plate to the bracket (2).
STEP 12 1
Stop the vacuum pump. NOTE: When installing, proceed in the reverse order to that of removal. Start the engine and operate the control levers. Stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
2
CD00G076
Take the control lever block (1) out from the bracket (2).
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-11
Swing shuttle block
STEP 6
Removal and installation NOTE: Refer to page 3 and carry out Steps 1 to 4.
1
STEP 1 To make installation easier, attach identification tags to all hydraulic hoses and electrical connections of the shuttle block.
STEP 2 Start the vacuum pump.
2
STEP 3 CD00G064
Provide for a container to recover any possible hydraulic fluid leaks.
Remove the screws (1), then remove the shuttle block (2) from its bracket.
STEP 4
NOTE: When installing, proceed in the reverse order to that of removal. Start the engine, operate the control levers, stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
CD00G063
Remove and seal the hydraulic hoses, remove the pressure detector, remove the junction unions, put plugs on the ports of the shuttle block, then discard the O-rings. NOTE: When installing, replace all O-rings with new Orings.
STEP 5 Stop the vacuum pump.
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-12
Cushion control valve Removal and installation
Servo control and return manifold block
NOTE: Refer to page 3 and carry out Steps 1 to 4.
Removal and installation
STEP 1
NOTE: Refer to page 3 and carry out Steps 1 to 4.
Open the left-hand side doors.
STEP 1
STEP 2
To aid installation, put identification tags on all the hydraulic hoses.
STEP 2 Start the vacuum pump.
2
STEP 3 Provide for a container to recover any possible hydraulic fluid leaks.
STEP 4 3 1 2 3 To aid installation, put identification tags on the hydraulic hoses.
3
STEP 3
1 3
Start the vacuum pump.
STEP 4
CS01N583
Remove and seal the hydraulic hoses.
Disconnect the hydraulic hoses from the cushion control valve (1). Plug the hydraulic hoses and the ports of the cushion control valve (1).
STEP 5
STEP 5
STEP 6
Stop the vacuum pump.
Remove the screws (1) then remove the block (2). Remove the junction unions (3), discard the O-rings, put plugs on the ports of the block.
STEP 6 Remove the screws (2) from the bracket and from the cushion control valve. Remove the cushion control valve. NOTE: When installing, proceed in the reverse order to that of removal. Start the engine, operate the control levers, stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
Lep SM4608007-0EN
Stop the vacuum pump.
NOTE: When installing, replace all O-rings with new Orings. NOTE: When installing, proceed in the reverse order to that of removal. Start the engine, operate the control levers, stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
Issued 09-07
Copyright © 8007-13
6 solenoid valve block
STEP 5
Removal and installation
To aid installation, put identification tags on the hydraulic hoses.
NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 6
STEP 1 Open the left-hand side door of the machine.
Start the vacuum pump.
STEP 7
STEP 2
Disconnect the hydraulic hoses connected to the solenoid valve block. Seal the ports with caps and the hoses with plugs.
STEP 8 Stop the vacuum pump.
STEP 9 Remove the screws and washers from the protective housing.
STEP 3 Put the protective housing away to make it easier to disconnect the connectors from the protective housing.
Loosen the retaining screws from the solenoid valve block. Remove the screws and washers, making sure to support it. Remove the solenoid valve block from its bracket.
STEP 10 For proper installation of the connections, mark the locations of the elbow unions. Fasten the solenoid valve block in a vice. Remove the elbow unions and the straight unions from the ports. Plug the solenoid valve block ports with plugs to avoid any penetration of foreign bodies.
STEP 4
1
NOTE: When installing, proceed in the reverse order to that of removal. Start the engine. Energise several times the solenoid valves (second speed selection, swing brake control, power boost, pilot cushion control cancellation, swing locking, negative control, boom priority, pilot pressure). Stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if necessary.
Disconnect the connectors (1) by pressing on the tongue fastener and then by pulling to separate them (the connectors are identified by rings of different colours).
Lep SM4608007-0EN
Issued 09-07
Copyright © 8007-14
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... Lep SM4608007-0EN
Issued 09-07
Copyright ©
Section 8008
8008
REMOVAL AND INSTALLATION OF THE SWING MOTOR
CNH
Lep SM4608008-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8008-2
TABLE OF CONTENTS SPECIAL TORQUE SETTINGS..................................................................................................................................... 2 SWING MOTOR............................................................................................................................................................. 3 Removal and installation ............................................................................................................................................ 3
SPECIAL TORQUE SETTINGS
+50
Swing motor retaining screws .....................................................................................................................295 -0
Lep SM4608008-0EN
Nm
Issued 09-07
Copyright © 8004-3
SWING MOTOR Removal and installation STEP 1
STEP 5
JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2
Remove the upper panel (2) retaining screws (1), then remove the upper panel (2).
Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 6
STEP 3
To facilitate installation, attach labels to all the hoses and hydraulic unions which are disconnected during removal.
STEP 7 Start the vacuum pump.
STEP 8 6 5 3 Disconnect the earth (-) cable (1) from the battery.
STEP 4 To prevent any fluid leaks when disconnecting hydraulic lines, connect a vacuum pump to the hydraulic reservoir (see Section 8000).
1
4 2
CD02E001
Attach identification tags to the hydraulic hoses. Remove the hoses (1), (2), (3), (4), (5) and (6). Plug the hoses and the unions. NOTE: When installing, replace all O-rings with new Orings.
Lep SM4608008-0EN
Issued 09-07
Copyright © 8008-4
STEP 9
STEP 13
Stop the vacuum pump.
To prevent any contamination of the gear oil, cover the reduction gear with a cloth or a suitable protection.
STEP 10
NOTE: When installing, follow the same procedure in the reverse order.
STEP 14 See Section 8001 and adjust the swing motor secondary relief valves. NOTE: Before operating the machine, start the engine, check the system for leaks and check the hydraulic oil level in the reservoir, top up if necessary.
Connect a suitable lifting device to the swing motor.
STEP 11 1 2
To facilitate reassembly, make an alignment mark (1) on the swing motor and on the reduction gear. Remove the retaining screws (2) from the hydraulic swing motor. NOTE: When installing, tighten the screws to torque (see special tightening torques on page 2).
STEP 12 Carefully lift the swing motor and move it away from the swing reduction gear. Move the swing motor away from the machine and place it on a clean workbench. NOTE: When installing, apply Loctite 504 to the mating surfaces between the reduction gear and the swing motor.
Lep SM4608008-0EN
Issued 09-07
Copyright ©
Section 8010 MAIN HYDRAULIC PUMP
CNH
Lep SM4608010-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8010
DISASSEMBLY AND ASSEMBLY
Copyright © 8010-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 3 SPECIAL TORQUE SETTINGS...................................................................................................................................... 3 REGULATOR ................................................................................................................................................................. 4 Exploded View ............................................................................................................................................................ 4 Sectional View ............................................................................................................................................................ 5 EXPLANATORY DIAGRAM OF REGULATOR OPERATION ........................................................................................ 7 HYDRAULIC PUMP ........................................................................................................................................................ 8 Exploded View ............................................................................................................................................................ 8 Cross-Sectional View .................................................................................................................................................. 8 Sectional View ............................................................................................................................................................ 9 PTO UNIT...................................................................................................................................................................... 11 Sectional View .......................................................................................................................................................... 11 Exploded View .......................................................................................................................................................... 12 REGULATOR DISASSEMBLY...................................................................................................................................... 13 HYDRAULIC PUMP DISASSEMBLY............................................................................................................................ 15 PTO UNIT DISASSEMBLY ........................................................................................................................................... 17 WEAR INSPECTION..................................................................................................................................................... 18 REGULATOR ASSEMBLY............................................................................................................................................ 20 HYDRAULIC PUMP ASSEMBLY.................................................................................................................................. 22 TROUBLESHOOTING .................................................................................................................................................. 24 REGULATOR ADJUSTMENT....................................................................................................................................... 26
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-3
SPECIFICATIONS See Section 1002.
SPECIAL TORQUE SETTINGS Pump: Screw (401)........................................................................................................................................................... 430 Nm Screw (406)............................................................................................................................................................. 29 Nm Plug (466) ............................................................................................................................................................... 36 Nm Plug (468) ............................................................................................................................................................. 170 Nm Plug (490) .............................................................................................................................................................. 8.8 Nm Plug (492) .............................................................................................................................................................. 9.8 Nm Pin (531) ............................................................................................................................................................... 430 Nm Piston (532)........................................................................................................................................................... 430 Nm Nut (808) ............................................................................................................................................................... 240 Nm Regulator: Screw (412), (413) .................................................................................................................................................. 29 Nm Screw (436), (438) .................................................................................................................................................. 12 Nm Plug (496) .............................................................................................................................................................. 8.8 Nm Locknut (630) ........................................................................................................................................................ 160 Nm Nut (801) ................................................................................................................................................................. 16 Nm Nut (802) ................................................................................................................................................................. 19 Nm PTO: Screw (435)............................................................................................................................................................. 98 Nm Plug (468) ............................................................................................................................................................... 74 Nm NOTE: The numbers within brackets refer to the diagrams from page 4 to 12.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-4
REGULATOR Exploded View
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-5
VIEW C
HYDRAULIC CIRCUIT
SECTION A-A
SECTION B-B
Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-6
Description 412 - HEX SCREW C.H.C 413 - HEX SCREW C.H.C 436 - HEX SCREW C.H.C 438 - HEX SCREW C.H.C 496 - PLUG 601 - CASING 611 - FEEDBACK LEVER 612 - LEVER (1) 613 - LEVER (2) 614 - CENTER PLUG 615 - ADJUSTING PLUG 621 - COMPENSATOR PISTON 622 - PISTON CASE 623 - COMPENSATOR ROD 624 - SPRING SEAT (C) 625 - OUTER SPRING 626 - INNER SPRING 627 - ADJUSTING RING (C) 628 - ADJUSTING SCREW (C) 629 - COVER (C) 630 - LOCK NUT 631 - PF SLEEVE 641 - PILOT COVER 643 - PILOT PISTON 644 - SPRING SEAT (Q) 645 - ADJUSTING RING (Q) 646 - PILOT SPRING 651 - SLEEVE 652 - SPOOL
Lep SM4608010-0EN
653 - SPRING SEAT 654 - RETURN SPRING 655 - SET SPRING 656 - BLOCK COVER 708 - O-RING 722 - O-RING 724 - O-RING 725 - O-RING 728 - O-RING 730 - O-RING 732 - O-RING 733 - O-RING 734 - O-RING 735 - O-RING 755 - O-RING 756 - O-RING 763 - O-RING 801 - NUT 814 - SNAP RING 836 - SNAP RING 858 - SNAP RING 874 - PIN 875 - PIN 876 - PIN 887 - PIN 897 - PIN 898 - PIN 924 - SET SCREW 925 - ADJUSTING SCREW (Q)
Issued 09-07
Copyright © 8010-7
EXPLANATORY DIAGRAM OF REGULATOR OPERATION
Regulator function diagram
330.7.01.01.55I
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-8
HYDRAULIC PUMP Exploded View
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-9
VIEW A
SECTION B-B
Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-10 983 - PIN 981 - PLATE 954 - SCREW 953 - SCREW 901 - BOLT 886 - PIN 885 - PIN 824 - SNAP RING 808 - NUT 806 - NUT 792 - RING BACK-UP 789 - RING BACK-UP 774 - SEAL 732 - O-RING 728 - O-RING 725 - O-RING 724 - O-RING 719 - O-RING 717 - O-RING 714 - O-RING 710 - O-RING 702 - O-RING 548 - PIN 545 - BALL 544 - STOPPER 2 443 - STOPPER 1 541 - SEAT 535 - STOPPER (S) 534 - STOPPER (L) 532 - SERVO PISTON 531 - PIN 530 - TILTING PIN ASSEMBLY 492 - PLUG
Lep SM4608010-0EN
490 - PLUG 468 - PLUG 467 - PLUG 466 - PLUG 406 - SCREW 401 - SCREW 314 - VALVE PLATE (FRONT) 313 - VALVE PLATE (REAR) 312 - VALVE BLOCK 271 - PUMP CASING 263 - COVER SEAL (REAR) 261 - COVER SEAL (FRONT) 251 - SUPPORT 214 - BUSH 212 - SWASH PLATE 211 - SHOE PLATE 157 - SPRING 156 - SPHERICAL BUSH 153 - HOLDER PLATE 152 - SHOE 151 - PISTON 127 - BEARING SPACER 124 - NEEDLE BEARING 123 - ROLLER BEARING 114 - 1st GEAR 113 - DRIVE SHAFT (REAR) 111 - DRIVE SHAFT (FRONT) 012 - CYLINDER BLOCK 05 - PTO ASSEMBLY 04 - GEAR PUMP
Issued 09-07
Copyright © 8010-11
PTO UNIT Sectional View
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-12
Exploded View
115 - IDLE-SHAFT 117 - 2nd GEAR 118 - 3rd GEAR 125 - BEARING 126 - CYLINDRICAL ROLLER BEARING 128 - BEARING SPACER 262 - COVER 326 - GEAR CASE
Lep SM4608010-0EN
435 - FLANGE SOCKET 468 - PLUG 710 - O-RING 728 - O-RING 825 - LOCKING RING 826 - LOCKING RING 827 - LOCKING RING 886 - PIN
Issued 09-07
Copyright © 8010-13
REGULATOR DISASSEMBLY NOTE: The numbers within brackets refer to the drawing from page 4 and 5. NOTE: Always keep the components from different pumps separate from one another. During disassembly of the pump, place the components on a rubber mat. Handle the components carefully. Always mark the position of the parts.
STEP 3
STEP 1
Remove the screws (412, 413) and then remove the regulator.
After removing the cover (629) subassembly, remove the outer spring (625), inner spring (626), and spring seat (624) from the compensation section, and pull out the adjusting ring (645), pilot spring (646), and spring seat (644) from the pilot section. • The adjusting ring (645) can be easily removed by pulling it out with an M4 bolt.
STEP 2
Remove the screws (438), and remove the cover (629). • The cover is assembled with an adjusting screw (628), adjusting ring (627), lock nut (630), hexagon nut (801) (802), and hexagon socket head stop screw (924). Do not loosen these screws and nuts. Doing so changes the adjusted pressure-flow setting.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-14
STEP 4
Remove the screws (436 and 438) and remove pilot cover (641). After you remove the pilot cover, remove set spring (655) from the pilot section.
STEP 7
Remove lever 2 (613). Leave pin (875) in. • Tweezers will facilitate the process.
STEP 5
Pull out pin (874) and remove feedback lever (611). Remove stop ring (814) to remove spring seat (653), return spring (654), and sleeve (651). • A snap ring (836) is fitted onto the sleeve (651). • Return spring (654) will pop out while removing stop ring (814); do not lose it.
STEP 6
• Push out pin (874) (pin dia. 4) from top with a fine steel rod. Avoid hitting lever (1) (612) during this process.
STEP 8 Remove lever (1) (612). Leave pin (875) in.
STEP 9 Pull out pilot piston (643) and spool (652).
STEP 10 Pull out piston case (622), compensating piston (621), and compensating rod (623). Now the regulator is completely disassembled. • Piston case (622) can be removed by pushing out the compensating rod (623) from the opposite side of the piston case. NOTE: The components are small. Be very careful not to lose them. Remove locking ring (858), and remove support plug (614) and adjusting plug (615). • Support plug (614) and adjusting plug (615) can be easily pulled out if you use an M6 bolt.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-15
HYDRAULIC PUMP DISASSEMBLY NOTE: The numbers within brackets refer to the drawing from page 4 to 12.
STEP 4
NOTE: Always keep the components from different pumps separate from one another. During disassembly of the pump, place the components on a rubber mat. Handle the components carefully, always mark the position of the parts.
STEP 1 Remove the oil drain port plug (468) and drain the oil from the pump casing (271). • Remove the plugs from both the front and rear pumps.
STEP 2 CD01G104
Place the pump horizontally with the regulator installation side facing down on the workbench and disconnect the pump casing (271) and valve block (312). • When placing the pump with the regulator installation side facing down, make sure that the workbench is covered with rubber plates or equivalent to prevent damage on the installation side. • When disconnecting the pump casing and valve block, remove the 1st gear at the same time.
STEP 5 CD01G103
Remove the screws (412, 413) and remove the regulator.
STEP 3 Loosen the screws (401), which lock the swash plate support (251), pump casing (271), and valve block (312). NOTE: If a gear pump and others are attached to the back side of the pump, this procedure should be done after disconnecting the gear pump and others. CD01G105
Remove the cylinder (012) straight out from the pump casing (271) toward the drive shaft (111), and remove the piston subassembly (151), holder plate (153), spherical bush (156), and cylinder spring (157) at the same time. • Be careful not to damage the sliding surfaces of the cylinder, spherical bush, shoes, and swash plate.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-16
STEP 6
STEP 10
CD01G106
CD01G109
Remove the retaining screws (406) and remove the seal cover (F) (261).
Remove the drive shaft (111) and 113) from the swash plate support using a plastic mallet.
• Remove the seal cover (F) with a bolt inserted in the tapping hole for easier operation.
STEP 11
• Handle with care when removing the seal cover (F), to prevent scratches on the oil seal, which is attached to the seal cover (F).
STEP 7 Remove the screws (406) and remove the seal cover (R) (263).
STEP 8
CD01G118
Remove the valve plates (313 and 314) from the valve block (312). NOTE: They may be removed during the step 4.
STEP 12
CD01G107
Remove the front flange (251) by gently tapping it with a plastic mallet. Discard the seal.
STEP 9
If necessary, remove the stopper (L) (534), stopper (S) (535), servo piston (532), tilting pin (531) from the pump casing (271) and needle bearing (124) from the valve block (312). • When removing the tilting pin, use appropriate tools to prevent damage to the top of the tilting pin. • Be careful not to damage the servo piston because Loctite is applied to the connecting part of the tilting pin and the servo piston. • The needle bearing should not be removed except when it wears out. • Do not loosen the hexagon nut for the valve block and swash plate support. Loosening the nut causes the flow rate to change. NOTE: Operation to be carried out in case of wear of the piston or the control pivot.
CD01G108
Remove the shoe plate (211) and swash plate (212) from the pump casing (271). Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-17
PTO UNIT DISASSEMBLY NOTE: The numbers within brackets refer to the drawing from page 11 and 12. NOTE: Disassemble PTO Subassembly following the steps described below after reading the entire disassembling instructions.
STEP 1
STEP 6
Choose a work area for disassembly. • Choose a clean area. • Place rubber plates or cloth on a workbench to prevent scratches on the parts.
STEP 2 Remove debris or rust on the surface of pump with cleaning oil or equivalent.
STEP 3 Remove the drain port plug (468) on the pump casing and drain oil. • Drain oil from each plug on the front pump and the rear pump.
STEP 4 Disconnect the flange socket and remove the gear pump.
STEP 5
CD01G111
Disconnect the retaining ring (827), remove the idler shaft (115), and pull out the 2nd gear (117), the roller bearing (126), and the bearing spacer (128). • The roller bearing (126) cannot be removed from the 2nd gear (117).
STEP 7
CD01G110
Disconnect the screws (435) and remove PTO Subassembly.
CD01G112
Disconnect the retaining ring (825) and remove the 3rd gear (118) and the ball bearing (125). • The ball bearing (125) cannot be removed from the 3rd gear (118). NOTE: Installation is done in the opposite order of disassembly; however, keep in mind the following notes. • Make sure to repair the damaged parts and prepare replacement parts beforehand. • Clean each part with solvent and install them after airblowing them. • When installing the sliding parts or bearings, make sure to apply clean lubricant. • Replace sealing parts such as O-rings and oil seals with new ones as a general rule. • Use torque wrenches for each mounting bolt and plugs, etc.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-18
WEAR INSPECTION Standard dimension / Replacement of parts recommended Pump types
Location
Part to be replaced
K3V63,
K3V112,
K3V180,
K5V80
K5V140
Play between piston/bore (D-d)
0.028 / 0.056 mm
0.039 / 0.067 mm
0.043 / 0.070 mm
0.0375 / 0.078 mm
Replace the pistons or the cylinder
Play at the shoe piston and the guide (A)
0-0.1 / 0.3 mm
0-0.1 / 0.3 mm
0-0.1 / 0.3 mm
0-0.1 / 0.35 mm
Replace the pistons and the piston retaining plate
Shoe thickness (t)
3.9 / 3.7 mm
4.9 / 4.7 mm
5.4 / 5.0 mm
5.4 / 5.0 mm
Replace the pistons and the piston retaining plate
Free height of cylinder springs (L)
31.3 / 30.5 mm
41.1 / 40.3 mm
47.9 / 47.1 mm
40.9 / 40.1 mm
Replace the springs
Height of the base plate and the spherical bushing (H-h)
19.0 / 18.3 mm
23.0 / 22.0 mm
23.7 / 22.7 mm
23.7 / 22.7 mm
Replace the base plate and the spherical bushing
K3V140
K5V200
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate (machined surface) Distribution machined plate (sliding contact surface) Swash plate (at the plate) Cylinder (sliding contact surface) Irregularity of each surface
d
Standard roughness after grinding
3-Z
Roughness of the surface at the wear limit
0.4 Z or lower (lapping)
D L
Piston to cylinder bore
Free heigh of cylinder spring (L)
clearance (D-d)
A h
t
Piston, shoes, and caulking section backlash (A)
H
Assembled height of holder plate and spherical bush (Hh)
Shoe thickness (t)
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-19
STEP 1 Check for cracks, breakage and pitting on the shafts, the cylinder block pump body.
STEP 2 Check for heavy wear, cracks, pitting, deep scratches, rough areas on the plate, the piston housing, the pistons, and the control spools.
STEP 3 If one of these conditions is present, change the component.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-20
REGULATOR ASSEMBLY NOTE: Assembly is done in the reverse order of disassembly, taking into account the following instructions: - Clean the components with detergent and dry them with compressed air. - Tighten the screws and plugs to the recommended torque. - Coat the moving parts with clean oil before assembling them. - Install new seals and O-rings.
STEP 1
STEP 7
Select the location for assembling the regulator. Find a clean location to assemble the regulator. Place a rubber plate or cloth on the work surface so as not to damage the parts.
Install pilot piston (643) into the negative control hole on casing.
STEP 2
STEP 8
• Ensure that the pilot piston slides smoothly without engagement.
Assemble the compensation rod (623) into the compensation opening on the casing (601).
STEP 3 The pin that is press-fitted onto the lever 1 (612) is to be inserted in the compensating groove. After you insert the pin, install lever 1 onto the pin that is pressfitted onto the casing.
STEP 4
The pin that is press-fitted onto lever 2 (613) is to be inserted in the groove on pilot piston. Insert the pin and install lever 2.
STEP 9 SPOOL
FEEDBACK LEVER
Install spool (652) and sleeve (651) into the spool hole on the casing. • Ensure that the spool and sleeve slides smoothly in casing without engagement. • The spool must be oriented properly.
STEP 5
LEVER (1) SIDE
LEVER (2) SIDE (SUPPORT PLUG ADJUSTING PLUG-SIDE
The pin that is press-fitted into support plug (614) goes into the pin hole on lever 2. Install the support plug (614) in this manner, and install locking ring (858).
STEP 10 Insert adjusting plug (615) and install the locking ring. • Ensure that you placed the support plug and the adjusting plug in the respective holes.
Install feedback lever (611), align the pinholes on the feedback lever, and insert pin (874).
• At this point, move the feedback lever to see it is not loose and there is no engagement.
• You can facilitate the process by slightly inserting the pin into the feedback lever beforehand. • The feedback lever must be facing the right direction.
STEP 6 Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-21
STEP 11
STEP 14
Install return spring (654) and spring seat (653) into the spool hole, and install stop ring (814).
Install cover (C) (629), into which you have already set adjusting screw (628), adjusting ring (C) (627), lock nut (630), hexagon nuts (801, 802), and set screw (924). Then fasten the screws (438) to complete the assembly.
STEP 12
Install set spring (655) into the spool hole, install compensating piston (621) and piston case (622) into the compensating hole, fit pilot cover (641), and fasten the screws (436).
STEP 13
Install spring seat (644), pilot ring (646), adjusting ring (Q) (645) into the pilot hole, then fit spring seat (624), inner spring (626), outer spring (625) into compensating hole. • The spring seat must face the right direction.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-22
HYDRAULIC PUMP ASSEMBLY NOTE: Assembly is done in the reverse order of disassembly, however, the following instructions need to be followed:
STEP 3
• Respect the reference marks made during disassembly. • Lubricate the seals and the sliding parts. • Do not mix the parts of the front and rear pumps. • Use light Loctite when installing the control pivot.
STEP 1
CD01G115
Install the drive shaft (111) which are attached with the roller bearing (123), bearing spacer (127) and stop ring (824) on the swash plate support (251). • Do not hit the drive shaft with a hammer, etc. • Fit the outer ring of the bearing with a light strokes of a plastic hammer and make sure that it is fit firmly using a steel bar or equivalent.
STEP 4 CD01G113
Fit a new O-ring on the flange (1). Install the flange (1) on the housing (2), respecting the reference marks made during disassembly.
STEP 2
CD01G116
Assemble the seal cover (F) (261) with the pump casing (271) and secure them with the screws (406). • Apply grease lightly on the oil seal inside the seal cover (F) CD01G114
Place the pump casing with the regulator installation side facing down, push down the tilting pin (531) of the swash plate, and install the swash plate (212) on the swash plate support (251) properly.
• Make sure not to damage the oil seal when handling it. • In case of a tandem pump attach the seal cover (R) or seal cover (F) in the same way.
• Make sure the swash plate moves smoothly by pushing it with finger tips of both hands. • Apply grease on the swash plate, swash plate support or other moving part for the easy installation of the drive shaft.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-23
STEP 5
NOTE: • Assemble the pump on the rear side first. • Be careful not to mix up the orientation of the valve block. • In case of the pump for clock wise rotation (viewed from the input shaft side) position of the discharge port :left side. • [position of the regulator : above] • In case of the pump for counter clock wise rotation (viewed from the input shaft side) position of the discharge port :right side. • [position of the regulator port : above] CD01G117
Assemble the piston cylinder subassembly (cylinder block (141), piston subassembly (151 and 152), retainer (153), spherical bush (156), cylinder spring (157), spacer (158)) and insert them into the pump casing aligning the phase angle of the spline with the spherical bush and cylinder.
• Insert the 1st gear in the valve block beforehand, and then couple the spline on the joint section of the drive shaft.
STEP 8
STEP 6
CDIG103
CD01G118
Clamp the feedback pin of the tilting pin on the feedback lever of the regulator, install the regulator, and fasten the screws (412 and 413).
Install the valve plate (313) on the valve block (312) with the pins aligned.
• Be careful not to mix up the regulator for the front use and the rear use.
• Be careful not to mix up the inlet and outlet direction on the valve plate.
STEP 9
STEP 7
Install the drain port plug (468) to complete the procedure.
CD01G119
Install the valve block (312) on the pump casing (271), tighten the screws (401) to the specifique torque.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-24
TROUBLESHOOTING 1) General precautions Following are countermeasures if you find abnormality during the operation of Kawasaki swash plate type axial piston pump and motor. General precautions are: a) Considerations before starting repair. Determine the characteristics of the abnormality before starting repair. Consider if the cause is originated from the wrong circuit, failure of regulator, or attached valve. Double check that the problem involves the pump motor. b) Before disassembling a system, make sure to read through the service manual. Conduct the disassembly in a correct manner. c) When disassembling a system, be careful not to allow dust to enter. d) Parts are finished precisely. Be careful not to damage them when handling. 2) Troubleshooting for the pump main body Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult to find the cause of the problem. Checking the following points is useful to identify the problem area. a) Filter check and drain oil check Check the filter element. Check if a considerable amount of contamination is found. It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders is seen. However, if the amount of metal dust is extremely high in the filter, the shoe might be damaged. Check drain oil of inside the pump casing, as well. b) Abnormal noise / abnormal vibration Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound repeats with regular frequency such as, a hunching sound in the regulator or hunching sound of the valve relief. If there is an abnormal vibration or sound, cavitation or damage inside the pump should be considered. c) When using two pumps. If piping uses two single pumps or two motors, change the pipe of each pump. By changing the pipe, the problem can be identified whether it is caused by a pump failure or a piping failure after the pump. 4) Perform pressure measurement. If the problem is related to the controlling function, examine the problem areas using pressure measurement tools instead of performing overhaul inspection.
Lep SM4608010-0EN
Issued 09-07
Copyright © 8010-25 3) Overload on the motor Causes
Countermeasures
Notes
Rotational speed-check if pressure is set higher than expected value.
Set pressure at an expected value.
Check if the torque set of the regulator is high.
Recheck the regulator.
Refer to the regulator instruction manual.
Damage and burning on the internal parts of the pump.
Replacement of damaged parts.
Check filter and drain oil for abnormal dust from abrasion.
Wrong piping for the regulator.
Correct the regulator piping.
4) When pump flow rate declines significantly or discharging pressure does not increase. Causes
Countermeasures
Notes
Faulty regulator.
Repair the regulator.
Refer to the regulator instruction manual.
Damage and burning on the internal parts of the pump.
Replacement of damaged parts.
Check filter and drain oil.
Attached faulty pump.
Replace damaged parts.
Disconnect the attached pump and check the shaft coupling section.
Attached faulty valve.
Check attached valve. (Check espe- Refer to the attached valve instruccially puppets and seat springs.) tion manual.
Wrong regulator piping.
Correct the regulator piping.
5) Abnormal noise / abnormal vibration Causes
Countermeasures
Notes
Cavitation
Prevention of cavitation. Check hydraulic oil for white turbidness.
Damage on the shoe caulking area.
Replacement of piston shoe, shoe plate or others.
Cracks on the cylinder
Replacement of the cylinder
Failure of pump installation
Reinstallation
Hunching of the regulator
Repair of the regulator
Refer to the regulator instruction manual.
Hunching of the relief valve on the attached valve
Repair the attached valve.
Refer to the attached valve instruction manual.
Lep SM4608010-0EN
- Boost pressure is too low. - Failure of auxiliary pump. - Air is drawn from the intake pipe. - Intake resistance is too high.
Issued 09-07
Copyright © 8010-26
REGULATOR ADJUSTMENT Regulator type:
KR3H-9N5A
Revolution (min-1)
1980 Adjusting screw (954) Fastening (turns)
+1/4
Changes in flow (L/min.)
-7.6
Adjusting screw (953) Fastening (turns)
+1/4
Changes in flow (L/min.)
+7.6
Adjusting screw (628) Fastening (turns)
+1/4
Changes in compensation control start pressure (MPa)
+1.8
Changes in input torque (N+m)
+91
Adjusting Maximum Flow
Adjusting Minimum Flow
Adjusting outer spring Adjusting Input Power Adjusting inner spring
Adjusting Flow Controlling Characteristics
Lep SM4608010-0EN
A
+2.17
Adjusting ring (627) Fastening (turns)
+1/4
Changes in flow (L/min.)
+13
Changes in input torque (N+m)
+61
Set screw (924) Fastening (turns)
+1/4
Changes in flow control start pressure (MPa)
+0.17
Changes in flow (L/min.)
+21
Issued 09-07
8011
Copyright ©
Section 8011 DISASSEMBLY AND ASSEMBLY OF THE CONTROL VALVE
CNH
Lep SM4608011-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8011-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 TOOLS REQUIRED ........................................................................................................................................................ 2 SPECIAL TORQUE SETTINGS...................................................................................................................................... 3 CONTROL VALVE .......................................................................................................................................................... 4 Description .................................................................................................................................................................. 4 Identifying the ports..................................................................................................................................................... 9 Disassembly.............................................................................................................................................................. 10 Inspection.................................................................................................................................................................. 14 Assembly .................................................................................................................................................................. 15 Troubleshooting ........................................................................................................................................................ 20
SPECIFICATIONS Weight of control valve .......................................................................................................................... See Section 1002 Safety valve settings.............................................................................................................................. See Section 8001
TOOLS REQUIRED 1. Loctite 262 2. Torque wrench OEM 6472, OEM 6474 and OEM 6476
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-3
SPECIAL TORQUE SETTINGS Spool assembly Screws (D) for the spools (3) to (7) and (8) to (11) .................................................................................... 24 to 26 Nm Screw for the spool (49)............................................................................................................................. 19 to 22 Nm Spool end (24) ........................................................................................................................................... 19 to 22 Nm Load holding valve (37) Plugs (A) and (F) ....................................................................................................................................... 28 to 30 Nm Plug (H)...................................................................................................................................................... 14 to 18 Nm Control valve assembly Relief valve (38) ....................................................................................................................................... 93 to 108 Nm Safety valves (39) ...................................................................................................................................... 78 to 88 Nm Safety valves (40) .................................................................................................................................. 123 to 127 Nm Relief valve (41) ..................................................................................................................................... 103 to 113 Nm Retaining screws (56) of the control valve sections ............................................................................... 356 to 394 Nm Plug (27) .................................................................................................................................................. 93 to 108 Nm Plug (42) ................................................................................................................................................ 103 to 113 Nm Plug (45) ................................................................................................................................................ 103 to 113 Nm Plug (50) .................................................................................................................................................... 73 to 79 Nm Plug (51) .................................................................................................................................................... 31 to 42 Nm Plug (52) ................................................................................................................................................ 116 to 128 Nm Plug (53) .................................................................................................................................................... 73 to 79 Nm Plug (66) .................................................................................................................................................. 93 to 108 Nm Plug (23) .................................................................................................................................................. 93 to 108 Nm Plug (63) .................................................................................................................................................... 14 to 18 Nm Cap retaining screws (34) and (54) ....................................................................................................... 103 to 113 Nm Cap retaining screws (69) ................................................................................................................ 194.5 to 215.5 Nm Cap retaining screws (12), (13), (63), (64), (72) and (73) ...................................................................... 103 to 113 Nm Cap retaining screw (67)............................................................................................................................ 38 to 42 Nm Plugs (91) .................................................................................................................................................. 49 to 59 Nm Cap retaining screws (75) .......................................................................................................................... 58 to 64 Nm Screw (55) ................................................................................................................................................. 58 to 64 Nm Screw (68) .............................................................................................................................................. 14.4 to 16 Nm
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-4
CONTROL VALVE Description 52
51
1 54
39
52
34
68
69 39 66
54 70 66
54
40 54
55 52
52 54
51
38
47 55
47
56 81 54
39
39 75 76
38
56 81 CS02K558
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-5
34 53
33
35
31 42
53
65
39
33
34
35
32
46 45
43 44
16 17 18
15
19 47
38
52
18 47
77
15 16
17
19 CS02K559
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-6
33
60
34
36 35
33 31
37
35
34
70 35
31
71
66
33
71 69
52
31
64
34
35
66
97
33
29
64
91
52 35 34 52
33
39
28
31 52 48 47
35
31
53 34
35
33
39
40 36
33
60
37 CS02K562
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-7
2
63
59 60
14 72
8
61
9 61
12 91 64
91 64
10 59
11
60
6 13 61
14
61 1
14 3
12
13 4 5 72
73 6
12
13 63
7 64 14
CS02K561
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-8
63
41
41
53
51
39
52
28 29
52
67
23 22
48
49
62 20
52
51 29 24 21 25 27 26 50 30
CS02K560
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-9
Identifying the ports NOTE: Refer to Section 8001.
Description 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.
Control valve housing Control valve housing Dipper spool 2 Bucket spool Boom spool 1 Travel spool Straight-line travel spool Dipper spool 1 Option spool Boom spool 2 Swing spool Cap Cap O-ring Check valve Spring Spacer O-ring Back up ring Spool Spring seat Spring Plug Spool Spring O-ring Plug Check valve Spring Check valve Check valve Check valve Spring Cap O-ring Check valve Load holding valve Main relief Safety valve Safety valve Safety valve Plug assembly Check valve Spring Plug O-ring Plug O-ring Spool Plug Plug Plug Plug Screw Screw Screw
Lep SM4608011-0EN
59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 75. 76. 77. 81. 91. 97.
O-ring O-ring O-ring O-ring Port plug O-ring Steel ball Plug Cap Screw Cap Screw O-ring Cap Cap Screw Plug O-ring Washer Plug Plug
Issued 09-07
Copyright © 8011-10
Disassembly
STEP 3
NOTE: Remove the control valve from the machine, see Section 8004.
59
61
General instructions
61
60
- Clean around the component to be removed and take care to ensure that no foreign matter enters the control valve.
61
- Label the parts removed and arrange them in a manner that makes assembly easier. - Since the spool is an integral part of the control valve body and the sleeve, do not replace the spool.
60
NOTE: The numbers in brackets refer to the views on pages 4 to 8.
Separating the sections NOTE: Remove the sections only if required. If disassembly is required, place the control valve body in a horizontal plane.
61
61 CS02K564
STEP 1
Remove the O-rings (59), (60) and (61).
Clean the outside of the control valve with a suitable cleaning solvent to eliminate all traces of impurities, grease and other foreign bodies. Dry, using low pressure compressed air.
Spool assembly STEP 1
STEP 2
Loosen and remove the screws (54) that fasten the caps (12) and (72) and remove the caps. NOTE: If necessary, remove the complete plug assembly (91) and the O-ring (64).
81 56
STEP 2 Remove the O-rings (14) from sections (1) and (2) of the control valve.
STEP 3 Remove the spools (3) to (7) and (8) to (11) from the control valve body as sub-assemblies, taking care not to damage them. NOTE: Identify each spool so that they can be put back in their respective housings during assembly.
STEP 4 Loosen and remove the screws (54) that fasten the caps (73) and (13) and remove the caps. NOTE: If required, remove the plug assembly (91) and the plug (97).
81 56 CS02K563
Separate the two sections (1) and (2) from the control valve by removing the screws (56) and the washers (81).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-11
STEP 5
STEP 4
Remove the O-rings (14) from sections (1) and (2) of the control valve.
Loosen and remove the spool assembly (49), then remove the spring seats and the spring.
NOTE: To avoid abrasion of the spool surface during disassembly of the spool assembly, use a vice with protective jaws and tighten the spool as close as possible to the head in order to avoid any deformity. When the threaded portion of the screw is coated with Loctite, heat the head of the screw using an industrial drier until removal becomes easy (normally the temperature should be in between 200 and 250°C). If this operation causes the spring to be deformed and malfunction, replace the spring.
Spool assembly (20)
STEP 6
Remove the spring (22).
B
C
B
D
NOTE: When removing the plug (23), make sure that you do not drop parts which are under pressure from the springs.
STEP 1 Loosen and remove the plug (23) and remove the O-ring (62).
STEP 2 STEP 3 B
E
A
CS01K596
Remove the spool screws (D) on the spring side of the spools (3) to (7) and (8) to (11). Remove the spring seats (B) as well as the springs (C). NOTE: In the spools (5) and (8), only remove the check valves, the springs, the O-rings, the back up rings and the plugs if it is necessary. If it is necessary to remove them, heat the periphery of the spool in order to make it easier to remove the plug.
Dipper load holding valve decompression spool 1 STEP 1 Loosen and remove the screws (68) that fasten the cap (67) and remove the cap (67).
STEP 2 Remove the O-ring (48) from the cap (67).
D
C CS02K568
Remove the spool (A) from the sleeve (B). Extract the sleeve (B) from the control valve body. Remove the piston (C), the O-ring (D) and the back-up ring (E).
Load holding block NOTE: Be careful when removing components, some parts are subject to spring pressure.
STEP 1 Loosen and remove the screws (54) and remove the caps (34).
STEP 2 Remove the springs (33), the check valves (31) and (32), and the O-rings (35) from the control valve body.
STEP 3
NOTE: The straight-line travel valve does not have springs or check valves (see cross-section H-H).
Remove the spool (49) from the control valve body taking care not to damage it.
STEP 3
NOTE: For disassembly of the spool, refer to the instructions previously cited for disassembly of spool assemblies.
Lep SM4608011-0EN
Loosen and remove the screws (54) and remove the caps (47).
Issued 09-07
Copyright © 8011-12
STEP 4
Remove the load holding valves (67)
Remove the spacer (17) from the control valve body, then remove the O-ring (18), the back-up ring (19) from the spacer (17).
NOTE: Be careful when removing components, some parts are subject to spring pressure.
STEP 5 Remove the spring (33) and the check valve (31) from the control valve body.
STEP 6 Loosen and remove the plug (52) (see cross-section CC).
STEP 7 Remove the spring (29) and the check valve (28) from the control valve body.
STEP 1 Loosen and remove the screws from the load holding valves (37) then remove the load holding valve.
STEP 2 Remove the O-rings (35) and (60) from the control valve body.
STEP 3 Remove the spring (33) and the check valve (36) from the control valve body.
STEP 8 Loosen and remove the plug (52) (see cross-section LL).
STEP 9 Remove the spring (29) and the check valve (28) from the control valve body.
STEP 10 Remove the spring (33), the check valve (31) and the O-ring (35) from the control valve body.
STEP 11 Loosen and remove the plug (45) and the O-ring (46).
STEP 12 Remove the spring (44) and the check valve (43) from the control valve body.
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-13
Load holding valve (37) H
Valves NOTE: Do not operate the valve components, as this will affect the pressure, otherwise see Section 8001 for the valve settings.
I 37
STEP 1
E F D G
C A
39
J
CS02C563
A
B CS02K566
NOTE: Be careful when removing components, some parts are subject to spring pressure.
Loosen and remove the safety valves (39) from the control valve body. Remove the O-ring (A) from the safety valve body.
STEP 2
STEP 1 Loosen and remove the plug (A) and remove the O-ring (B).
38
A
STEP 2 Remove the spring (C), the spring seat (D) and the spool (E).
STEP 3 CS02C560
Loosen and remove the plug (F) and remove the O-ring (G).
Loosen and remove the relief valve (38) from the control valve body. Remove and discard the O-ring (A).
STEP 4
STEP 3
Disassemble the plug (H) and the O-ring (I). NOTE: The steel ball (J) is a press fit, do not remove it.
A
42
B
C
CS01K600
Loosen and remove the plugs (42) and remove the O-rings (A), (B) and (C).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-14
Auxiliary assembly STEP 1 Loosen and remove the screws (54) from the caps (69) and remove the O-rings.
STEP 2
Cleaning Clean all the parts removed with clean oil. Dry with compressed air and place each part on a clean sheet of paper or vinyl for inspection.
Inspection
Loosen and remove the two plugs (66) and remove the O-rings and the back up rings.
Inspect the surface of each part for scratches, abrasion and other damage.
Plug assembly STEP 1
1.
Check that there are no scratches or dents on the non-return load check valve seat in the control valve body and that there are no traces of rust or contaminants.
2.
Check that there are no scratches or dents on the periphery of the spool. Use an abrasive product to remove any small scratches.
3.
Check that all sliding surfaces are moving freely. Check for the absence of foreign matter in holes and in grooves.
4.
Replace the springs in case of damage, deformity or wear and tear.
5.
Replace all O-rings and back up rings with new ones.
6.
After removing the caps and plugs, ensure that there is no trace of paint at the level of the port of the body or on the rim of the plug. (Any trace of residual paint is likely to cause contamination that could cause the system to malfunction and lead to possible leaks).
Loosen and remove the plug (42) and remove the O-ring (see cross-section J-J).
STEP 2 Loosen and remove the plug (63) from its port (see cross-section Z-Z).
STEP 3 Loosen and remove the plugs (52) and remove the O-rings.
Precautions before assembly Before beginning assembly, check the quantity of the parts, be sure of their final position and get all the required tools ready.
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-15
Assembly
Dipper load holding valve decompression spool 1 STEP 1
Spool assembly NOTE: Take care not to apply too much Loctite, it could seep through inside the spool and cause it to malfunction. NOTE: If the spool (5) boom section 1 (opposite the spring) and the spool (8) dipper section 1 (spring side) have been removed for assembly, proceed in the following manner:
STEP 1
Apply Loctite 242 on the threaded portions of the spool (49) and install the spring seats, the spring and the spool end.
STEP 2 Install the spool in a vice with protective jaws. Tighten the end of the spool to torque (see page 3).
Load holding valve (37)
Install the check valve and the spring in the spool, install the back up ring and the O-ring on the plug. Apply Loctite 242 on the threaded portion of the plug. Install the spool in a vice with protective jaws and tighten the plug at the end of the spools (5) and (8).
I
H
37 E
STEP 2 Apply Loctite 242 on the spring side on the threaded portions of the spools (3) to (7) and (8) to (11). Install the spool in a vice with protective jaws.
F
STEP 3
G B
C
B
D
D
C
J A
B CS02K566
STEP 1 Install the plug (H) complete with a new O-ring (I). CS01K596
Install the spring seat (B) the spring (C), spring seat (B) on the screw (D) and tighten it on the spool to torque (see page 3).
NOTE: Respect the positions of the O-rings and back up rings. If installations are not carried out in the correct order, the O-rings will be lacerated.
STEP 2 Install the plug (F) complete with a new O-ring (G).
STEP 3 Lubricate and install the spool (E) in the valve (37), install the spring seat (D), install the spring (C), install a new O-ring (B) on the plug (A). Install the plug (A) and tighten to torque (see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-16
Valves
STEP 3
NOTE: Do not operate the valve components, as this will affect the pressure, otherwise see Section 8001 for the valve settings.
A
42
B
C
STEP 1
A
38
CS01K600 CS02C560
Install the main relief (38) equipped with an O-ring (A). Tighten to torque (see page 3).
Install the plugs (42) complete with an O-ring (A), (B) and (C). Tighten to torque (see page 3).
Load holding block STEP 1
STEP 2
Install the O-rings (35) in the control valve housings, dipper sections 1 and 2, boom sections 1 and 2, swing and bucket sections, install the check valves (31) and the springs (33).
STEP 2 A
39 CS02C563
Install the safety valves (39) complete with an O-ring (A). Tighten to torque (see page 3).
Install the caps (34) and fasten them using screws (54). Tighten to torque (see page 3).
STEP 3 Install the O-rings (35) in the travel control valve section, install the check valves (32) and the springs (33).
STEP 4 Install the caps (34) and fasten them using screws (54). Tighten to torque (see page 3).
STEP 5 Install the O-ring (35) in the control valve straight-line travel section housing. NOTE: The straight-line travel valve is not equipped with springs or check valves.
STEP 6 Install the cap (34) using screws (54). Tighten to torque (see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-17
STEP 7 Install the check valve (15) and the spring (16) (see cross-section I-I), install the spacer (17) complete with an O-ring (18) and a back up ring (19). NOTE: Respect the positions of the O-rings and back up rings. If installations are not carried out in the correct order, the O-rings will be lacerated.
STEP 8 Install the cap (47) using screws (54) and tighten to torque (see page 3).
STEP 9 Install the O-ring in the option section (see cross-section E-E), install the check valve (31) and the spring (33). Install the cap (34) and fasten it using screws (54). Tighten to torque (see page 3).
NOTE: Respect the positions of the O-rings and back up rings. Any wrong installation will cause lacerations and external leaks.
STEP 3 Install the load holding valve (37) and fasten it using screws (54). Tighten to torque (see page 3).
Auxiliary assembly STEP 1 Install the caps (69) equipped with an O-ring (71) and fasten them using the screws (70). Tighten to torque (see page 3).
STEP 2 Install the plugs (66) complete with an O-ring and a back up ring. Tighten to torque (see page 3).
STEP 10 Install the check valve (43) and the spring (44) on the travel portion (see cross-section G-G). Install the plug (45) complete with an O-ring (46). Tighten to torque (see page 3).
STEP 11 Install the check valve (28) and the spring (29) on the dipper portion 1 (see cross-section C-C). Install the plug (52) equipped with an O-ring. Tighten to torque (see page 3).
Load holding valve STEP 1 Install the O-rings (60) and (35) on the control valve dipper section 1 (see cross-section D-D) and boom section 1 (see cross-section F-F).
STEP 2 Install the check valve (36) and the spring (33).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-18
Spool assembly (20)
STEP 3
STEP 1 D
Install the caps (73) and the caps (13) on the control valve body and fasten them using screws (54). Tighten to torque (see page 3).
E
B
A
STEP 4 Install the caps (12) and the caps (72) on the control valve body and fasten them using screws (54). Tighten to torque (see page 3).
C CS02K568
Install the O-ring (D) and the back up rings (E) on the sleeve (B). Install the piston (C) and the spool (A) in the sleeve (B). Install the assembly in the control valve body.
STEP 2 Install the spring (22) inside the plug (23) equipped with an O-ring (62). Screw the plug on the control valve body. Tighten to torque (see page 3).
Dipper load holding valve decompression spool 1
NOTE: Check the proper positioning of the caps (72) and (73).
STEP 5 Install the plug (97) equipped with an O-ring on the short cap of the option section (see cross-section E-E). Tighten to torque (see page 3).
STEP 6 Install the plug (91) equipped with an O-ring (64) on the long cap of the option section (see cross-section E-E). Tighten to torque (see page 3).
STEP 1
Plug assembly STEP 1
Install the spool assembly (49) in the control valve body without forcing it.
Install the plug (42) equipped with an O-ring. Tighten to torque (see page 3) (see cross-section J-J).
NOTE: Ensure that it is functioning properly by making it slide manually.
STEP 2
STEP 2
Install the plug (63) in its port. Tighten to torque (see page 3) (see cross-section Z-Z).
Install the cap (67) equipped with an O-ring (48) and fasten it using screws (68). Tighten to torque (see page 3).
Spool assemblies (3) to (7) and (8) to (11) STEP 1 Install the O-rings (14) on the control valve body.
STEP 2 Install the assembled spools (3) to (7) and (8) to (11) in the ports of the control valve body. NOTE: Ensure that the spool is installed in its original port, install it without pressing too hard. After installing the spool, make it slide manually to check its proper functioning.
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-19
STEP 3 Install the plugs (52) equipped with an O-ring. Tighten to torque (see page 3).
NOTE: For installation of the control valve, see Section 8004.
Assembling the sections STEP 1 59
61
61
60
61 60
61
61
CS02K564
Install new O-rings (61) and (60).
STEP 2 56 81
56 81 CS02K563
Assemble the two sections (1) and (2) using screws (56) and washers (81). Tighten to torque (see page 3).
Lep SM4608011-0EN
Issued 09-07
Copyright © 8011-20
Troubleshooting Control valve in general Problems Spool does not move.
Possible causes Oil temperature has abnormally risen.
Remove any part causing resistance to oil flow in piping.
Dirty hydraulic oil
Change oil and clean circuit at the same time.
Over-tightening of piping port joints
Check torque.
Deformed valve housing by incorrect mounting
Loosen mounting bolts and check their condition.
Pressure is too high.
Check pressure by placing a pressure gauge between pump and cylinder port.
Deformed spool
Replace valve as an assembly.
Damaged return spring
Replace damaged parts.
Dislocated spring or cap
Loosen cap first, and then center and retighten it.
Temperature is not uniform inside the valve.
Warm up entire circuit.
Valve is blocked with dirt.
Eliminate dirt (flush).
Dislocated spring or cap
Check pilot valve and pilot relief pressure.
Lack of pilot pressure
Check seals in cylinder for damage.
Oil bypasses spool.
Check spool for damage.
Oil leakage from overload relief valve
Clean valve housing seats and relief valve seats.
Oil leakage from anti-drift valve
Disassemble anti-drift valve and clean seat section in each part. If damage is found in seat section, replace poppet or apply lapping to poppet together with the section. If any abnormality is found on anti-drift valve, replace spool and sleeve at the same time because they are press-fit.
Load check valve is blocked with dirt.
Disassemble and clean check valve.
Damage on poppet or seats in the check valve
Replace poppet or apply lapping to poppet and seats.
Load cannot be held.
Load drops when switching spool from neutral to raised position.
Countermeasures
Relief valve Problems Pressure does not rise at all.
Possible causes Main poppet, sleeve or pilot poppet sticks and keeps open, or seats in valve are blocked with dirt.
Unstable relief pressure
Seats in pilot poppet are damaged.
Incorrect relief pressure
Wear in seats due to dirt
Replace relief valve.
Piston or main poppet sticks.
Looseness in locknut and adjuster
Lep SM4608011-0EN
Countermeasures
Reset pressure and tighten locknut to specified torque.
Issued 09-07
Copyright © 8011-21 Oil leakage
Damage on relief valve seats Replace relief valve. Each part sticks due to dirt. Replace O-rings for adjuster or in mounting section.
Worn O-rings Hydraulic system in general Problems
Hydraulic system malfunctions or does not operate at all.
Lep SM4608011-0EN
Possible causes
Countermeasures
Faulty pump
Check pressure or replace pump.
Faulty relief valve
Replace relief valve.
Faulty cylinder
Repair or replace it.
High load pressure on pump
Check circuit pressure.
Cracks on the valve
Replace valve as an assembly.
Spool does not move with a complete stroke.
Check spool for its movement.
Oil level in tank is too low.
Refill hydraulic oil.
Filter blockage in circuit
Clean or change filter.
Restricted circuit piping
Check piping.
Issued 09-07
Copyright © 8011-22
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4608011-0EN
Issued 09-07
8012
Copyright ©
Section 8012 DISASSEMBLY AND ASSEMBLY OF THE ATTACHEMENT CYLINDERS
CNH
Lep SM4608012-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8012-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 SPECIAL TORQUE SETTINGS...................................................................................................................................... 3 SPECIAL TOOLS ............................................................................................................................................................ 4 CYLINDERS.................................................................................................................................................................... 6 Boom cylinder description .......................................................................................................................................... 6 Dipper cylinder description ......................................................................................................................................... 8 Bucket cylinder description ...................................................................................................................................... 10 Disassembly ............................................................................................................................................................. 12 Inspection ................................................................................................................................................................. 20 Assembly ................................................................................................................................................................. 21
SPECIFICATIONS See Section 1002.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-3
SPECIAL TORQUE SETTINGS Boom cylinder Piston nut..........................................................................................................................14 500 Nm (10 694.63 lbf ft) Bearing retaining screw ...................................................................................1140 ± 206 Nm (840.82 ± 151.94 lbf ft) Retaining clip retaining screw (15)...........................................................................31.5 ± 5.9 Nm (23.23 ± 4.35 lbf ft) Piping retaining screw (5 A) ...................................................................................62.6 ± 11.7 Nm (46.17 ± 8.62 lbf ft) Piping retaining screw (5 B) ...................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft) Hydraulic pipes retaining screw (4)......................................................................92.4 ± 17.3 Nm (68.15 ± 12.75 lbf ft) Piston nut screw ....................................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft) Dipper cylinder Piston nut..........................................................................................................................27 900 Nm (20 577.95 lbf ft) Bearing retaining screw ..................................................................................1560 ± 294 Nm (1150.59 ±216.84 lbf ft) Retaining clip retaining screw (15)...........................................................................31.5 ± 5.9 Nm (23.23 ± 4.35 lbf ft) Piping retaining screw (5) ......................................................................................62.6 ± 11.7 Nm (46.17 ± 8.62 lbf ft) Hydraulic pipes retaining screw (4)......................................................................145 ± 27.5 Nm (106.94 ±20.28 lbf ft) Piston nut screw ...................................................................................................96.8 ± 18.2 Nm (71.39 ±13.42 lbf ft) Air bleeder (48) ........................................................................................................44.1 ± 2.9 Nm (32.52 ± 2.13 lbf ft) Bucket cylinder Piston nut..........................................................................................................................14 500 Nm (10 694.63 lbf ft) Bearing retaining screw ...................................................................................1140 ± 206 Nm (840.82 ± 151.94 lbf ft) Retaining clip retaining screw (15)...........................................................................31.5 ± 5.9 Nm (23.23 ± 4.35 lbf ft) Piping retaining screw (5) ......................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft) Hydraulic pipes retaining screw (4)......................................................................92.4 ± 17.3 Nm (68.15 ± 12.75 lbf ft) Piston nut screw ....................................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft)
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-4
SPECIAL TOOLS OEM 9797 Hydraulic cylinder repair bench OEM 9798 Piston nut screw PE.174E-220 Hydraulic/electric pump OR CAS 10918 Hydraulic cylinder repairing bench OR E/SCRS1 Hydraulic cylinder repair bench including: - Repair bench - Electric hydraulic motor-pump assembly - Piston nut fastening wrench
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-5
OEM 9797 OR E/SCRS1
PE-174E-220
OEM 9798
CAS10918
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-6
CYLINDERS Boom cylinder description 28
26
20 44
24 27
21
23
43
22
42
15 16
1
47 11
25 17
41 7
10
4
8 19
34
35
6
36
33
37
5A
39 40
38
48
15
45 16 46 17 7 6
18
5B 44 8 43 9
4
CS02F584A
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GREASE FITTING NOT USED NOT USED SCREW SCREW WASHER PIPE CLAMP HYDRAULIC PIPE O-RING HYDRAULIC PIPE O-RING NOT USED NOT USED NOT USED SCREW LOCKING WASHER RETAINING CLIP SCREW BEARING SCREW STEEL BALL PISTON NUT PISTON SEAL BACK-UP RING SEALING RING SEALING RING SHIM NOT USED NOT USED NOT USED NOT USED O-RING BACK-UP RING RING SEAL BACK-UP RING WIPER SEAL RETAINING RING BUSHING SEAL CUSHION BUSHING ANTI-DUST SEAL BUSHING CYLINDER ROD CYLINDER BARREL O-RING BUSHING
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-8
Dipper cylinder description 6 5 7
4
8
9
33 34
19
15 16 17
48 39
1
4
40 35 37 36
44 43
18 38 5
10
11
6 22
7
5 6
23
7
26
20 21 44
24
43
8 47 27 42 41 17 45
46
16 15
CS02F586A
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GREASE FITTING NOT USED NOT USED SCREW SCREW WASHER PIPE CLAMP HYDRAULIC PIPE O-RING HYDRAULIC PIPE O-RING NOT USED NOT USED NOT USED SCREW LOCKING WASHER RETAINING CLIP SCREW BEARING SCREW STEEL BALL PISTON NUT PISTON SEAL NOT USED SEALING RING SEALING RING NOT USED NOT USED NOT USED NOT USED NOT USED O-RING BACK-UP RING RING SEAL BACK-UP RING WIPER SEAL RETAINING RING BUSHING SEAL CUSHION BUSHING ANTI-DUST SEAL BUSHING CYLINDER ROD CYLINDER BARREL O-RING BLEED SCREW
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-10
Bucket cylinder description
33 34 19 39 40 35
38 37 36
44 8
4 1
43
18
9
4
11
44
10
43 17 16 15 46
7 6 5
16
8 15 45
42
23
27
26
24
28
22
20 21
47
CS02F585
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
GREASE FITTING NOT USED NOT USED SCREW SCREW WASHER PIPE CLAMP HYDRAULIC PIPE O-RING HYDRAULIC PIPE O-RING NOT USED NOT USED NOT USED SCREW LOCKING WASHER RETAINING CLIP SCREW BEARING SCREW STEEL BALL PISTON NUT PISTON SEAL NOT USED SEALING RING SEALING RING SHIM NOT USED NOT USED NOT USED NOT USED O-RING BACK-UP RING RING SEAL BACK-UP RING WIPER SEAL RETAINING RING BUSHING NOT USED CUSHION BUSHING WIPER SEAL BUSHING CYLINDER ROD CYLINDER BARREL O-RING
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-12
Disassembly
STEP 3
NOTE: The boom, dipper and bucket cylinders are basically identical in construction. What changes is the hydraulic tube connections. Before installing the cylinder in the repair stand, remove the hydraulic tubes.
Bucket cylinder
STEP 1 Boom cylinder NOTE: The numbers within brackets in the following steps refer to the boom cylinder schematic on page 6. 1. Remove the grease fitting (1) from the cylinder. 2. Remove the screws (4) and disconnect the hydraulic tubes (8) and (10) from the cylinder. 3. Remove the screw (5), the washer (6) and the pipe clamp (7). Remove the hydraulic tubes (8) and (10) from the cylinder. Remove and discard the two Orings (9) and (11).
NOTE: The numbers within brackets in the following steps refer to the bucket cylinder diagram on page 10. 1. Remove the grease fittings (1) from the cylinder. 2. Remove the screws (4). Disconnect the hydraulic pipes (8) and (10) from the cylinder. 3. Remove the screws (5), the washers (6) and the pipe clamps (7). Remove the hydraulic tubes (8) and (10) from the cylinder. Remove and discard the two O-rings (9) and (11). 4. Remove the screws (15), the washers (16) and the circlip (17). NOTE: As an example, the repairing bench CAS 10918 is used.
STEP 4
4. Remove the screws (15), the washers (16) and the circlip (17).
STEP 2 Dipper cylinder NOTE: The numbers within brackets in the following steps refer to the dipper cylinder schematic on page 8. 1. Remove the screws (4) and disconnect the hydraulic tubes (8) and (10). 2. Remove the screws (5), the washers (6) and the pipe clamps (7). Remove the pipes (8) and (10) from the cylinder. Remove and discard the two O-rings (9) and (11). 3. Remove the screws (15), the washers (16) and the circlips (17).
Lep SM4608012-0EN
JD00620A
Install suitable bushings on the cylinder head stock chuck wings.
Issued 09-07
Copyright © 8012-13
STEP 5
STEP 8
JD00621A
Tighten the bushing retaining screws.
JD00625A
Connect lifting equipment, if necessary, to the cylinder. Position the cylinder in the repair stand with the rod end of the cylinder at the head stock chuck. Loosen the retaining screws of the tail stock chuck wings. When positioning the cylinder rod end on the head stock chuck wing, be sure that the chuck wing bushings are centred in the rod bushing. Install the screw and nuts to secure the cylinder rod end to the repair stand.
STEP 6
STEP 9
JD00623A
Install the stop pins on the boom tail stock.
STEP 7
JD00626A
On the cylinder repair stand, loosen the retaining screws of the tail stock chuck wings. When positioning the cylinder barrel end on the head stock chuck wing, be sure that the bushings are centred in the cylinder barrel bushing. Install the screw and nuts to secure the cylinder barrel end to the repair stand.
JD00624A
Install suitable bushings on the cylinder tail stock chuck wings. Tighten the retaining screws. Install the chuck wings on the cylinder tail chuck. Tighten the locking screws. Use the scale on the face of the chuck to aid in centering the chuck wings.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-14
STEP 10
STEP 12
JD00627A
JD00629A
Check and ensure that the chuck wings are centred on the repair stand centre line using scales scribed on the head and tail stock chucks.
Raise the cylinder barrel (46) support to support the cylinder barrel. Tighten the nuts to lock the support in position. Remove the lifting equipment.
NOTE: The numbers within brackets in the following steps refer to the boom cylinder, dipper cylinder and bucket cylinder schematics on pages 6, 8 and 10.
STEP 13
STEP 11
JD00630A
To make reassembly easier, draw alignment marks on the cylinder barrel (46) and the bearing (19). Remove the screws (18). JD00628A
Raise the cylinder rod (45) support to support the cylinder rod. Tighten the nuts to lock the support in position.
STEP 14
JD00631A
Place a container beneath the bearing and cylinder barrel to catch any hydraulic oil that may still be inside the cylinder. Start the hydraulic pump to remove the rod from the cylinder barrel.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-15
STEP 15
STEP 18
Connect lifting equipment, if necessary, to the cylinder barrel (46) and remove from the repair stand.
D B
STEP 16 A
C A
JD00635A
Move the bearing (19) away from the piston (23).
Check that both stop bars (A) are installed to prevent the head stock (B) chuck from turning. Remove the tail stock chuck wings and install the wrench (C) on the tail stock. Check that the wrench is centred on the chuck and tighten the screws (D).
STEP 17
STEP 19
JD00632A
E 18
JD00633A
JD00636A
Push the head stock chuck towards the piston nut (22) and, if necessary, remove the stop bars (A) and turn the chuck until the wrench (E) engages the piston nut.
JD00634A
Remove the screws (20) from the piston nut (22). Turn the cylinder rod and remove the ball (21).
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-16
STEP 20
STEP 22
JD00637A
Loosen the tail stock chuck screws. Tighten the wrench nuts on the piston nut (22). Check that the wrench is centred by using the scale on the chuck.
STEP 21 B
JD00639A
Start the hydraulic pump by pressing on the pedal to loosen the piston nut. At the end of the stroke, remove the two stop bars; if necessary, depress the rear of the pedal to retract the cylinder rod just enough to enable removal of the stop bars. Depress the rear of the pedal to retract the cylinder rod to lower the toggle assembly as far as possible on the circular plate then install the stop bars.
STEP 23 Repeat Step 22, if necessary, until the piston nut has been loosened.
STEP 24 A JD00638A
Lower the toggle assembly (B) as far as possible on the circular plate and install the stop bars (A).
JD00640A
Remove the piston nut (22) from the rod.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-17
STEP 25
STEP 28
JD00641A
JD00644A
Remove the shim (28) from the rod.
Remove the two sealing rings (26) from the piston.
STEP 26
STEP 29
23
24 26
27 B
A
47 JD00642A
Remove the piston (23) then remove the bearing rod.
STEP 27
25 JS00645A
Install the piston (23) in a vice (A) with protective jaws (B). Using a suitable tool, cut or break the seal ring (24). Remove the seal ring and discard. Remove and discard the two back up rings (25). Remove the piston from the vice.
JD00643A
Remove the two sealing rings (27) from the piston.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-18
STEP 30
JD00647A JD00646A
Lep SM4608012-0EN
Use a suitable tool to remove the O-ring (47). Scrap the O-ring.
Issued 09-07
Copyright © 8012-19
STEP 31 34 38
37
33
35 40
36
A
39 JS00649A
JD00650A
JD00652A
Remove and discard the O-ring (33) and back up ring (34). Remove and discard the back up ring (37) and the seal (36). Remove and discard the buffer ring (A) consisting of a ring (35). Remove and discard the wiper ring (38).
STEP 32 40
JD00651A
39 JS00653A
With a suitable tool, remove the retaining ring (39) from the bearing. Place the bearing on a press and with a suitable drift, force the ring (40) out of the bearing.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-20
STEP 33
Inspection
NOTE: The bucket cylinder does not incorporate a seal on the cushion ring.
STEP 1
Remove and discard the seal (41) from the cushion ring (42). Remove the cushion ring (42).
STEP 34 NOTE: Do the following step only if inspection indicates that the bushings (44) require replacement.
Inspect the seals, U-rings, back up rings, and O-rings prior to installation for any imperfections, tears, or other damage. If the seals or the bushings are worn out or damaged, replace the component(s). Ensure seals and bushings are installed correctly with no twisting of the seal or bushing. Install all new seals and rings wet with hydraulic oil.
STEP 2 Check the sliding parts for wear or damage such as scratches, dents, or bent parts. Small scratches can be removed with a hone or crocus cloth.
44 43
STEP 3 Check for cracks in the welding or other damage.
STEP 4 Measure the internal diameter of the bushings (44). If the internal diameter of the bushings is greater than the specifications, replace the bushing(s). JD00654A
43 44
JD00655A
Remove the four wipers (43) from the cylinder rod and cylinder barrel. Use a suitable press and drift and remove the two bushings (44) from the cylinder rod and cylinder barrel.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-21
Assembly
STEP 3
NOTE: The numbers within brackets in the following steps refer to boom cylinder, dipper cylinder and bucket cylinder schematics in this section on pages 6, 8 and 10.
40
STEP 1 43 44 19
JS00659A
Using a suitable press and drift, install the bushing (40) in the bore of the bearing (19). JD00655A
STEP 4
43
40
44
39 JD00654A
Using a suitable press and drift, install the two bushings (44). Install the four new wipers (43) with the lip side of the wipers facing out.
JS00653A
Install the retaining ring (39) in the groove of the bearing (19).
STEP 2 NOTE: The bucket cylinder does not incorporate a seal in the cushion ring. Install the cushion bushing (42) on the cylinder rod (45). Install a new seal (41) in the cushion bushing.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-22
STEP 5
JD00650A
Install a new O-ring (33) and back up ring (34). Install a new wiper ring (38). Install a new U-ring (36) and back up ring (37). Install a new buffer ring (A), consisting of a ring (35).
JD00652A
JD00651A
38
37
34
35
33
40
36
A
39 JS00649A
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-23
STEP 6
STEP 8
JD00647A
JD00642A
Install the bearing (19) then the piston (23) on the cylinder rod.
STEP 9
JD00646A
Coat a new O-ring (47) with clean hydraulic oil. Install the O-ring in the centre groove of the piston.
STEP 7
JD00641A
Install the shim (28) on the piston rod behind the piston.
24
26
STEP 10
27
23
B
A
47
25 JS00645A
(A) (B)
VICE HARD WOOD JD00640A
Place a tapered tool over the piston (23). Coat a new seal ring (24) with clean hydraulic fluid. Slide the seal onto the tool and install it in the groove of the piston on top of the O-ring (47). Install two new back up rings (25). Install four new sealing rings (26) and (27) in the grooves of the piston.
Lep SM4608012-0EN
Install the piston nut (22) on the cylinder rod and hand tighten.
Issued 09-07
Copyright © 8012-24
STEP 11
STEP 13
Carry out Steps 4 to 12 of disassembly to install the cylinder rod in the repair stand.
STEP 12
A B
C
D
C JD00660A
JD00637A
E
Remove the toggle assembly (A) and the cylinder (D) on the RH side of the repair stand, by removing the stop bars (B) and the pins (C). Install the toggle assembly and cylinder (D) on the left side of the repair stand. Operate the hydraulic pump by depressing the foot pedal to extend the rod end of the hydraulic cylinder to rotate the circular plate clockwise to tighten the piston nut. At the end of the stroke, remove the two stop bars; if necessary, depress the rear of the pedal to retract the cylinder rod just enough to enable removal of the stop bars. Depress the rear of the pedal to retract the cylinder rod to lower the toggle assembly as far as possible then install the stop bars. Repeat this step as required to tighten the piston nut to torque (see "Specifications").
JD00636A
Carry out Steps 19 to 21 of disassembly to install wrench (E) on the piston nut (22).
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-25
STEP 14
STEP 16
JD00634A
JD00637A
Loosen the nuts to remove the wrench from the piston nut (22). Move the repair stand support away from the cylinder rod.
STEP 17
JD00633A
Install the steel ball (21) in the piston nut (22). Install the screw (20) in the nut. Tighten the screws to torque (see "Specifications").
STEP 15
JD00662A
Using suitable means of lifting, install the tube on the repair stand in order to align the cylinder rod (45) and the bearing. Install the tube and the bearing (19) by aligning the markers.
A
20
21 JS00661A
(A) AWL
After tightening the screw (20) to the required torque, caulk the screw at two places.
Lep SM4608012-0EN
Issued 09-07
Copyright © 8012-26
STEP 18
STEP 21 Dipper cylinder NOTE: The numbers within brackets in the following steps refer to the dipper cylinder schematic on page 8. 1. Install the circlips (17) on the cylinder, using washers (16) and screws (15). Tighten the screws to torque (see "Specifications"). 2. Install the hydraulic pipes (8) and (10) on the circlips (17), using clamps (7), washers (6) and screws (5). Tighten the screws to torque (see "Specifications").
JD00630A
Install the screws (18) and tighten to torque.
STEP 19 Attach a suitable lifting device to the cylinder. Remove the screws and chuck wings to free the cylinder from the repair stand.
3. Install the two new O-rings (9) and (11) on the cylinder. Connect the hydraulic pipes (8) and (10) to the cylinder using the screws (4). Tighten the screws to torque (see "Specifications"). 4. Install the new O-ring (3) on the pipe (8). Install the plug (2). Tighten the plug to torque (see "Specifications"). 5. Install the grease fitting (1) in the cylinder.
STEP 20
STEP 22
Boom cylinder
Bucket cylinder
NOTE: The numbers within brackets in the following steps refer to the boom cylinder schematic on page 6. 1. Install the circlip (17) on the cylinder, using washers (16) and screws (15). Tighten the screws to torque (see "Specifications"). 2. Install the two hydraulic tubes (8) and (10) on the circlip (17), using clamps (7), washers (6) and screws (8). Tighten the screws to torque (see "Specifications"). 3. Install two new O-rings (9) and (11) on the cylinder. Connect the hydraulic pipes (8) and (11) to the cylinders. Fasten the pipes using screws (4). Tighten the screws to torque (see "Specifications"). 4. Install two new O-rings (3) on the pipes. Install two plugs (2) and tighten the plugs to torque (see "Specifications").
NOTE: The numbers within brackets in the following steps refer to the bucket cylinder schematic on page 10. 1. Install the circlip (17) on the cylinder barrel, using washers (16) and screws (15). Tighten the screws to torque (see "Specifications"). 2. Install the hydraulic pipes (8) and (10) on the circlip (17), using clamps (7), washers (6) and screws (5). Tighten the screws to torque (see "Specifications"). 3. Install the two new O-rings (9) and (11). Connect the hydraulic pipes (8) and (10) to the cylinder and fasten the pipes with screws (4). Tighten the screws to torque (see "Specifications"). 4. Install the grease fittings (1) in the cylinder.
5. Install the grease fitting (1) in the cylinder.
Lep SM4608012-0EN
Issued 09-07
Copyright ©
8013
Section 8013 DISASSEMBLY AND ASSEMBLY OF THE CONTROL LEVERS
CNH
Lep SM4608013-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8013-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 CONTROL LEVER ......................................................................................................................................................... 3 Description ................................................................................................................................................................. 3 STRUCTURE ................................................................................................................................................................. 4 FUNCTIONS .................................................................................................................................................................. 4 OPERATION .................................................................................................................................................................. 5 CONTROL LEVER ......................................................................................................................................................... 7 Disassembly ............................................................................................................................................................... 7 Inspection ................................................................................................................................................................. 10 Assembly ................................................................................................................................................................. 11 TROUBLESHOOTING ................................................................................................................................................... 5
SPECIFICATIONS Torque settings Orifice plate retaining screws ..................................................................................................................20.6 ± 1.5 Nm Universal joint on control lever ................................................................................................................47.1 ± 2.9 Nm Lock-nut on universal joint ......................................................................................................................68.6 ± 4.9 Nm Primary pressure
Maximum pressure 6.9 MPa
Secondary pressure
0 to 4.4 (Maximum control pressure) MPa
Allowable back pressure
Maximum 0.3 MPa
Rated flow
20 L/min
Operating inclination
± 19°, ± 25° (single)
Mass
1.9 kg
Piping
To obtain better response, suitable piping is inner diameter 8, length 3 M. In addition, the return oil should be directly returned to the tank to avoid the influence of back pressure.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-3
CONTROL LEVER Description
1 20 2
3 19
4 5
6 7
17
8
18
9
22
10 11 12
16 15
13 21 14 18 CRPH06B059G01
1 2 3 4 5 6 7 8 9 10 11 12 13
LOCK-NUT PROTECTIVE BOOT DISC PUSH-ROD PLATE PLUNGER ASSEMBLY O-RING SPRING SEAT SPRING SPRING SPOOL CONTROL LEVER BODY ORIFICE PLATE
Lep SM4608013-0EN
14 15 16 17 18 19 20 21 22
HEXAGONAL ALLEN-TYPE SCREW O-RING BUSHING PUSH-ROD SEAL WASHER LIP-SEAL UNIVERSAL JOINT PLASTIC PIN WASHER
Issued 09-07
Copyright © 8013-4
STRUCTURE The structure of a pilot valve is as shown in the assembly sectional drawing. The casing has openings along the vertical axis, in which pressure reducing valves are integrated. The pressure reducing valve section consists of spools (201), springs (241) for setting secondary pressure, return springs (221), spring seats 1 (216) and washers 2 (217). The spring (241) for setting secondary pressure is configured to obtain reduced secondary pressures of 0.49 to 0.98MPa (depending on models). The spool (201) is pushed against the push rod (212) by the return spring (221). As the push rod (212) is pressed down when the operating part of the handle is inclined, the spring seat 1 (216) is also lowered at the same time, as a result, the settings of the spring for setting secondary pressure (241) change. The casing (101) and port plate (111) have oil entry ports P (Primary pressure) and exit ports T (Tank), and the secondary pressure is delivered from the ports 1, 2, 3 and 4.
FUNCTIONS 1) Basic functions The pilot valve is a valve designed for controlling the strokes and directions of the control valve spool. This is achieved by acting output pressures from the pilot valve on the end of the control valve spool. To meet requirements for this function, the pilot valve is composed of the following segments: Entry port (P) through which the hydraulic pump supplies oil Multiple output ports (1, 2, 3 and 4) which are designed to apply pressure supplied from the entry port on the end of spool in the control valve. Tank port (T) which is required to control the output pressures described above. Spool which connects an output port to the entry port or tank port. Mechanical measures including springs which act on the spool described above in order to control output pressure.
2) Major component functions The function of the spool (201) is to receive pressure oil supplied from the hydraulic pump at the port P, and by switching the oil paths, to introduce the pressure oil at port P to output ports (1, 2, 3 and 4) or introduce to port P. It is the role of the spring for setting secondary pressure (241) to determine output pressure by acting on this spool (201). The push rod (212) is inserted in the plug (211) so that it can slide and change the deflection of the spring for setting secondary pressures (241). The return spring (221), regardless of the output pressure, acts on the casing (101) and spring seat (216) to return the push rod (212) in the direction of zero displacement, ensuring that the spool (201) can return to its neutral position. This return spring also functions as reaction spring, to give good operational responsiveness.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-5
OPERATION This section describes the operation of pilot valves based on the Hydraulic Oil Circuit Drawing (Figure 1) and Operation Description Diagrams (Figures 2 through 4). Figure 1 shows a typical usage of the pilot valve. Figure 1. An example of pilot valve use
5
6
1
3
4
2
CRPH06B106E
1 2 3
PILOT VALVE PILOT PUMP MAIN PUMP
4 5 6
CONTROL VALVE HYDRAULIC MOTOR HYDRAULIC CYLINDER
1) When the handle is in neutral (Figure 2) The force of the spring for setting secondary pressures (241), which determines the output pressure on the pilot valve, is not applied on the spool (201). Therefore, the spool (201) is pushed upward by the return spring (221) (by the spring seat 1 (216)), the output ports (2, 4) are connected with the port T. At this moment, the output pressure is equal to the tank pressure.
216 241 221 201
000-7-06-01-15B
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-6
2) When the handle is inclined (Figure 3) As the push rod (212) is pushed in by inclining the handle, the spool (201) (spring seat 1 (216)) moves downward and the port P and ports (2, 4) are connected. As a result, the oil supplied from the pilot pump flows into ports (2, 4), thus generating pressure.
212
216 201
000-7-06-01-15c
3) When the handle is held (Figure 4) When the pressures at ports (2, 4) rise up to a pressure equivalent to the force of the spring (241), which was set by inclining the handle, the hydraulic force and the force of the spring are in balance. When the pressures at ports (2, 4) are more than the set pressure, ports (2, 4) and port P close and ports (2, 4) and port T open. When the pressures at ports (2, 4) are less than the set pressure, ports (2, 4) and port P open and ports (2, 4) and port T close. As a result, secondary pressures are maintained constantly. (T) Port T (P) Port P
241 T P
000-7-06-01-15d
4) Operation in ranges where the handle is greatly inclined (depends on models) In some models, when the handle is inclined more than a given degree, the upper end of the spool touches the bottom part of the push rod bore and the output pressure remains equal to the port P pressure as connected. What's more, if a structure where the spring seat and spring are integrated in the inside of push rod is used, when the handle is inclined more than a given degree, the bottom part of the push rod bore contacts the spring, and the force of the spring causes the secondary pressure gradient to change. Afterwards, the bottom part of the push rod bore contacts the upper end of the spring seat; thus the output pressure remains equal to the port P pressure as connected.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-7
CONTROL LEVER Disassembly
STEP 3
NOTE: The numbers in brackets in the following steps refer to the schematic on page 3. Always handle high precision parts with the greatest care to prevent them being damaged by being knocked or dropped. The components of the control lever may rust due to contamination and humidity if they are left without protection after disassembly. If work has to be stopped, the components must be protected against contamination or corrosion.
STEP 1 CD00G089
Remove the disc from the control lever.
STEP 4
CD00G087
Install the control lever in a soft-jawed vice. Remove the protective boot.
STEP 2 CRPH06B110A
CD00G088
Remove the lock-nut from the control lever. CRPH06B111A
Used the special tool 380001055. Install two nuts on the universal joint and tighten them fully. While holding the upper nut, turn the lower nut anti-clockwise to unscrew the universal joint. Remove the universal joint from the control lever. NOTE: Carefully remove the universal joint to prevent the plate and the push-rods, which are under pressure from the springs, from flying out too quickly.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-8
STEP 5
STEP 7
CD00G091
CD00G093
Remove the plate.
Remove the spool assembly from the control lever.
NOTE: Mark the components removed in the following steps to facilitate their insertion in the correct bore during assembly.
STEP 8
STEP 6
CD00G094
Turn the control valve the other way up in the vice. Unscrew and remove the six screws and the sealing washers. CD00G092
Depending on the condition of the return springs, the friction of the O-rings can keep the plunger assemblies in place in the body. In this case, use a flat screwdriver to remove the plunger assemblies. Slide the screwdriver into the external groove of the plunger assembly, taking care not to damage the plunger assembly. This must be done carefully, since the plunger assembly can be thrown out suddenly, due to the action of the return springs.
STEP 9
CD00G095
Remove the orifice plates and the O-ring from the body. Scrap the O-ring.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-9
STEP 10
STEP 12
JD00774A
Remove the bushing from the body of the control lever.
STEP 11
CD00G098
Remove the spool (17) and the spring (18) from the plunger assembly (6).
STEP 13
CD00G096 CD00G099
Remove the push-rod (4) from the plunger assembly (6).
STEP 14
CD00G097
Press the spring down a few millimetres so as to free the spool (11) from the spring seat (8). Separate the spool (11) from the spring (10) and the washer (22). Keep these components together for the reassembly procedure.
Lep SM4608013-0EN
CD00G100
Remove and scrap the plunger assembly O-ring.
Issued 09-07
Copyright © 8013-10
Inspection
STEP 15
Change all the seals and O-rings which have been removed. Also change the washers on all screws which have been removed.
STEP 1 Inspect the spools to ensure that the finish is not damaged, that they are not bent or damaged in any other manner. Make sure that the spool slides freely in the control valve body bore. If defects are found, change the entire control valve.
STEP 2 CD00G101
Remove and scrap the plunger assembly seal.
STEP 16 Cleaning the components: 1. Soak them in a suitable cleaning solvent until contamination and oil are removed. Components can be damaged if they are washed while they are still contaminated. 2. Final washing: Immerse the components in a clean receptacle containing a suitable cleaning solvent. Impart a rotary motion to the receptacle so as to wash the inner surface of the components as well. Dry the components with a clean cloth. NOTE: Never dry them with compressed air. Dust and water contained in the air will damage and corrode their surfaces. 3. Corrosion prevention: Apply an anti-rust product to all the components.
JS00784A
Inspecting the controls. Change the components if wear on the shaft pin and seal create play in the controls greater than 2 mm.
STEP 3 If it is impossible after inspection of the parts to determine the cause of an abnormal noise or a reduction in primary pressure, change the control lever.
NOTE: Components can rust if left in the open air after cleaning.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-11
Assembly
STEP 3
Carry out the assembly with the very greatest care. Do not hit or force the components, since that will damage them and cause seizure or oil leaks which would result in impaired performance of the machine. Before reassembly, remove all traces of metal particles or foreign bodies from all components. Check that there are no burrs on the components and remove them with an oil stone. Replace all O-rings and thrust rings with new components. Lubricate the O-rings and thrust rings to prevent any damage during assembly. Tighten all cap screws to the specified torque. Plug all orifices with plugs to prevent any contamination of the control lever by dust after reassembly.
A CD00G103
Install the orifice plate (13) with the plastic pin (21) in the orifice (A) in the control lever body.
STEP 1
STEP 4
JD00774A
Install the control lever body bushing.
STEP 2
CD00G104
Install the hexagonal Allen-type cap screws and the sealing washers in the orifice plate (13). Tighten the screws and retighten them alternately to a torque of 20.6 ± 1.5 Nm.
STEP 5
CD00G102
Install the O-ring in the groove in the control lever body.
CD00G105
Assemble the spool assembly by installing the washer (22), the spring (10) and the spring seat (8) on the spool (11).
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-12
STEP 6
STEP 8
CD00G106
CD00G108
Turn the control lever the other way up in the vice. Install the return spring and the complete spool assembly in the body, respecting the positions noted during steps 5 to 7 (disassembly).
STEP 7
19
4 CI00G509
Install the lip seals (19) with their ends as shown above.
STEP 9 CD00G107
Install the O-ring on the plunger.
CD00G109
Coat the surfaces of the push-rod (4) with hydraulic fluid and install it in the plunger (6).
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-13
STEP 10
STEP 13
CD00G110
CD00G112
Install the spool (17) and the spring (18) in the plunger (6).
Install the plate and retain it by means of the universal joint.
STEP 11
STEP 14
CD00G111
CRPH06B110A
Install the plunger in the body. Depending on the condition of the return springs, the friction of the O-rings may keep the plungers in place in the body.
STEP 12 Repeat steps 5 to 11 for the other three bodies.
CRPH06B111A
Used the special tool 380001055. Tighten the universal joint to a torque of 47.1 ± 2.9 Nm (34.7 ± 2.1 lb-ft).
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-14
STEP 15
STEP 17
CD00G113
Install the disc on the universal joint. Tighten until the disc touches the four push-rods equally.
CD00G115
Place a few spots of grease on the push-rods.
STEP 18
STEP 16
CD00G116 CD00G114
Install the protective boot (2) on the control lever.
Install the lock-nut and tighten it to a torque of 68.6 ± 4.9 Nm while holding the flats on the disc (3) with a flat wrench.
Lep SM4608013-0EN
Issued 09-07
Copyright © 8013-15
TROUBLESHOOTING It is not easy to find the faulty part. The following table lists some possible problems. As repairs are not easy, refer to the possible causes and countermeasures in the table. The table below shows general symptoms/possible causes and countermeasures. However, as a machine's trouble is generally caused not by a single faulty component but by other related components as well, it may be necessary to apply measures other than those listed in the Table. The table shown below does not necessarily include all possible causes and remedies. Therefore, the technician in charge of repairs must further investigate problems and their causes as necessary. Problem Secondary pressure doesnot rise.
Causes 1.Lower primary pressure
Countermeasures Ensure given primary pressure
2.Breakage and fatigue of secondary Replace with new one pressure spring (241) 3.Abnormally large gap between Replace as a remote valve complete spool (201) and casing (101) assembly
Unstable secondary pressure
High secondary pressure
Lep SM4608013-0EN
4.Loose handle section
Disassemble/assemble and replace handle section
1.Engaged sliding part
Repair engaged part
2.Fluctuations in tank line pressure
Direct return to oil tank
3.Entrapped air in piping
Bleed air by several operations
1.High tank line pressure
Direct return to oil tank
2.Engaged sliding part
Repair engaged part
Issued 09-07
Copyright © 8013-16
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4608013-0EN
Issued 09-07
Copyright ©
Section
DISASSEMBLY AND ASSEMBLY OF THE CONTROL PEDALS
CNH
Lep SM4608014-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8014
8014
Copyright © 8014-2
TABLE OF CONTENTS TORQUE SETTINGS ..................................................................................................................................................... 2 CONTROL PEDAL ......................................................................................................................................................... 3 Description ................................................................................................................................................................. 3 FOOT CONTROL ........................................................................................................................................................... 4 Disassembly ............................................................................................................................................................... 5 Inspection ................................................................................................................................................................... 6 Assembly ................................................................................................................................................................... 6
TORQUE SETTINGS Cover retaining screws .............................................................................................................................53.9 to 63.7 Nm Cam articulation pin locking screw (apply Loctite 241) ............................................................................13.3 to 16.1 Nm Cap screw ....................................................................................................................................................3.9 to 5.8 Nm
Lep SM4608014-0EN
Issued 09-07
Copyright © 8014-3
CONTROL PEDAL Description 5 7 9
6
10
3
11 8
12 2
13
14
4 30
19
15
21
16
20
17
22
18
25
23
26
24
27 28
1 29
CS02A503
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BODY COVER LOCKING SCREW CAM SHAFT BOOT BUSHING CAM BRAKE NUT SCREW RETAINING SCREW CAP RETAINER PLUG O-RING CONTROL ROD
Lep SM4608014-0EN
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
PISTON SPRING SPRING SPRING SEAT BALL RETAINER BUSHING WASHER SPRING SEAT SPRING COMPRESSION SPRING WASHER WASHER SPOOL PLUG
Issued 09-07
Copyright © 8014-4
FOOT CONTROL In neutral the foot control is a closed center hydraulic valve. The inlet oil from the pilot pump is blocked at both regulator spools. The ports (1) and (2) are ported inside of the valve back to tank through a hole drilled in the end, and a cross drilled hole in the regulator spool. There are two springs for each regulator spool. The larger diameter spring provides the return of the foot pedal and this spring is the resistance the operator feels in his foot. Typically the return springs are stronger in foot control than in hand control. If the dust cover under the foot control is torn, replace it. This will help prevent contamination from wearing the U-seals on the push rods. The gap between the push rod and the screw can be adjusted. A too tight adjustment can cause partial actuation of the spool. The contact area between the push rod and the screw should be lightly lubricated with grease. As the foot control is moved, the push rod will push on both large and small diameter springs. The smaller spring will push the spool and block of the return passage through the top meetering notches. The bottom metering land will open a passage and allow pilot oil out to the work spool of the travel control spool. As the travel spool moves and compresses the spring in the control valve, the pressure will increase and push up on the bottom of the regulator spool. When the pressure of the oil pushing on the travel spool equals the force of the spring behind the regulator spool the bottom metering land will block the pilot supply. When the force of the spring equals the force of the pressure on the spool, the spool is in a balanced position to maintain a proportional pressure with the compression of the spring. The foot control must be moved further to compress the small spring and push the regulator spool further to increase the pressure again. The foot control is nothing more than an adjustable pressure regulator, and the operator provides adjustment.
Lep SM4608014-0EN
Issued 09-07
Copyright © 8014-5
Disassembly
STEP 10
Always handle high precision parts with the greatest care to prevent them being damaged by being knocked or dropped. The components of the control pedal may rust due to contamination and humidity if they are left without protection after disassembly. If work has to be stopped, the components must be protected against contamination or corrosion.
Remove the O-ring (14) from the plug (13).
NOTE: The numbers in brackets in the following steps refer to the description on page 3.
Remove the springs (17), (18), the spring seat (19), the ball (20), the retainer (21) and the bushing (22).
NOTE: Clean around the foot control pedal and take care to prevent any foreign material entering the system.
STEP 13
STEP 1 Tighten the control pedal in a vice with protective jaws. Remove the bellows (5).
STEP 2 Remove the locking screw (3) from the cam shaft.
STEP 3 Remove the cam shaft (4) using a drift, as well as the ring (6).
STEP 4
STEP 11 Remove and label the control rod (15), as well as the piston (16).
STEP 12
Remove the washer (23) and the spring seat (24).
STEP 14 Remove the spring (25) and the compression spring (26).
STEP 15 Remove the washers (27) and (28).
STEP 16 Remove and mark the spool (29).
STEP 17 Remove the plug (30).
Identify the position of the cam (7) in relation to the cover (2) and remove the cam.
STEP 5 Remove the brake nut (8) as well as the screw (9).
STEP 6 Remove the retaining screw (10).
STEP 7 Identify and remove the cover assembly (2). NOTE: Repeat steps 1 to 7 for the other control pedal body.
STEP 8 Remove the cap (11) and the retainer (12).
STEP 9 Remove the plug (13).
Lep SM4608014-0EN
Issued 09-07
Copyright © 8014-6
Inspection
Assembly
STEP 1
NOTE: Immerse all parts in clean hydraulic fluid in order to guarantee proper lubrication when installing and restarting operation.
Check for cracks, distortion or blocking of the springs. If any one of these defects is found, replace the spring.
STEP 2 Check the spools to ensure that their finish is not damaged, that they are not twisted, or chipped etc. Ensure that the spools slide smoothly in the bore of the control pedal body. If defects are found, change the entire control pedal.
STEP 1 Fasten the spool (29) in a vice equipped with soft jaws. Install the following in the order shown : the washers (27) and (28) and the compression spring (26). NOTE: If the installation is performed incorrectly, this can cause a change in the secondary pressure.
STEP 3
STEP 2
Check the sleeves and the clips to ensure that their finish is not damaged, that they are not twisted, cracked or chipped. If any one of these defects is found, replace the damaged part.
Carefully install the spool assembly (29), in the body (1), install the spring (25), the spring seat (24) and the washer (23).
STEP 4
NOTE: Repeat steps 1 and 2 for the three other ports of the control pedal.
Check the bores for damage, internal damage of housings, or signs of internal wear at the level of the control pedal. If the control pedal is damaged, replace the entire assembly.
STEP 3
STEP 5
STEP 4
Discard all the O-rings and use new O-rings.
Install the piston (16) and the control rod (15) in the body (1).
Install the bushing (22), then the ball (20), the retainer (21), the spring seat (19) and the springs (17) and (18).
STEP 5 Install the O-ring (14) on the plug (13).
STEP 6 Install the retainer (12) in the plug (13).
STEP 7 Install the plug assembly (13) in the body (1).
STEP 8 Install the cap (11) on the plug (13). NOTE: Repeat steps 1 to 8 for the other control pedal port.
Lep SM4608014-0EN
Issued 09-07
Copyright © 8014-7
STEP 9 Assemble the cover assembly (2) on the body (1) in its original position. Fasten them using screws (10).
STEP 10 Install the screw (9) on the cam (7) using the brake nut (8).
STEP 11 Assemble the cam (7) on the cover (2). Install the bushing (6) and the cam shaft (4). The surface of the cam must be parallel with the cover surface (2).
STEP 12 Incline the cam and apply grease to the cam articulation and to the steel ball.
STEP 13 Assemble and tighten the screws (3) to the torque specified on page 2.
STEP 14 Assemble the upper portion of the boot on the cam, apply a humidity inhibitor in the cover groove to avoid oxidation, then assemble the lower portion of the boot on the cover.
Lep SM4608014-0EN
Issued 09-07
Copyright © 8014-8
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4608014-0EN
Issued 09-07
Copyright ©
Section 8015
OF THE SIX SOLENOID VALVES BLOCK
CNH
Lep SM4608015-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8015
DISASSEMPLY AND ASSEMBLY
Copyright © 8015-2
TABLE OF CONTENTS SIX SOLENOID VALVES BLOCK................................................................................................................................... 3 Assembly Drawing ...................................................................................................................................................... 3 Theory of operation ..................................................................................................................................................... 4 Disassembly and assembly......................................................................................................................................... 5 Inspection.................................................................................................................................................................... 6 Troubleshooting .......................................................................................................................................................... 7
Lep SM4608015-0EN
Issued 09-07
Copyright © 8015-3
SIX SOLENOID VALVES BLOCK Assembly Drawing
Normally open type solenoid: S2
Normally closed type solenoid: SP, S1, S3, S4, S5
1.
BODY
12.
BINDING BAND
2.
SPOOL
13.
BINDING BAND
3.
SPOOL
14.
BINDING BAND
4.
SPRING
15.
BINDING BAND
5.
SPRING
16.
SOLENOID
6.
ADAPTOR
17.
O-RING
7.
SNAP RING
18.
SCREW
8.
NAME PLATE
19.
PLUG
9.
SPRING WASHER
20.
PLUG
10.
BINDING BAND
21.
RIVET
11.
BINDING BAND
Lep SM4608015-0EN
Issued 09-07
Copyright © 8015-4
Theory of operation
The hydraulic fluid supplied from the port P is fed to the solenoid operated directional valves S1 to S5 when the valve SP is energized. The hydraulic fluid is then fed to the ports C1 to C5 depending on whether or not the valves S1 to S5 are energized. Electromagnetic selector valves S1, S3, S4 and S5: Oil passes through when energized Electromagnetic selector valve S2: Oil passes through when not energized
Lep SM4608015-0EN
Issued 09-07
Copyright © 8015-5
Disassembly and assembly TIGHTENING TORQUE 1.7 TO 2.0 Nm
O-RING SO - NA - A022
TIGHTENING TORQUE 1.7 TO 2.0 Nm O-RING SO - NB - P18
ELECTRONIC SELECTOR VALVE SP, S1, S3, S4, S5 => ITEM N° (2) ASSEMBLY ELECTRONIC SELECTOR VALVE S2 => ITEM N° (3) ASSEMBLY
NOTE: Disassemble the valve with due attention not to damage the O-ring and other parts, and store the parts in a safe place. If there is any flaw on the O-ring, replace it with a new one. Be careful to assemble the parts in the correct orientation and without forgetting any of the parts. When assembling, reverse the order of disassembling and pay attention not to allow any foreign matters such as dirt to get into the valve.
STEP 1 Remove the mounting bolts from the solenoid (C) and remove the coil part. (Tool: 3 mm Hexagon wrench)
STEP 4 Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove the adapter (6).
STEP 5 Assemble the valve by reversing the order of disassembling. When tightening the core, pay attention not to damage the edges of the flat portion of the core. When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and pay attention not to damage the O-ring.
STEP 2 Remove the tube, while paying attention not to damage the edges of the flat portion of the core. However, if the core is removed, replace the O-ring (A) with a new one. (Tool: 23 mm spanner)
STEP 3 Take out the spools (2) and (3) and the springs (4) and (5).
Lep SM4608015-0EN
Issued 09-07
Copyright © 8015-6
Inspection
1.
Clean all parts using suitable cleaning solvent. Immerse the solenoid valve housing in a cleaning solvent for several minutes to dissolve dirt or other foreign matter inside the solenoid valve housing. Use low pressure compressed air to blow out any foreign matter from interior of valve housing. Dry parts using clean cloths.
2.
Inspect springs for cracks, distortion, or evidence of permanent mis-setting. Replace a spring if any of these defects are observed.
3.
Check for cracks, holes, deformities and other signs of wear on the spools. Check that the spools slide easily in the bores of the solenoid valve block. If any of the above conditions is seen, replace the solenoid valve block.
4.
Check that the internal threading is not worn out and that the interior of the solenoid valve block shows no signs of wear. If any of the above conditions is seen, replace the solenoid valve block.
5.
Measure the play between the spool groove and the spool. The clearance =ØD - Ød must be approximately 0.01 mm. If this is not the case, change the solenoid valve block.
Lep SM4608015-0EN
Issued 09-07
Copyright © 8015-7
Troubleshooting Problem Spool malfunction
Solenoid malfunction
Cause
Action
Foreign matters galling the spool
Remove the foreign matters, dismount the valve, perform flashing, or replace the fluid.
Damaged parts or abnormal wear
Replace the valve.
Terminal disconnection
Insert the terminal.
Damaged coil
Replace the solenoid.
Broken lead wire Fluid leakage to outside Loose bolts
Lep SM4608015-0EN
Tighten the bolt to the specified torque.
Damaged O-ring
Replace the O-ring.
Loose hex socket plug
Fasten the plug.
Issued 09-07
Copyright © 8015-8
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4608015-0EN
Issued 09-07
Copyright ©
Section 8016
8016
DISASSEMBLY AND ASSEMBLY OF THE CUSHION CONTROL VALVE
CNH
Lep SM4608016-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8016-2
TABLE OF CONTENTS SPECIAL TORQUE ....................................................................................................................................................... 2 CUSHION CONTROL VALVE ...................................................................................................................................... 3 Description ................................................................................................................................................................. 3 System drawing ......................................................................................................................................................... 4 Changed over to "SOFT" ........................................................................................................................................... 5 Arm OUT, operating ................................................................................................................................................... 6 Arm OUT, stopped ..................................................................................................................................................... 7 Changed over to "SOFT" ........................................................................................................................................... 8 Disassembly .............................................................................................................................................................. 9 Inspection ................................................................................................................................................................ 11 Assembly ................................................................................................................................................................. 11
SPECIAL TORQUE Plug (7).................................................................................................................. 60 Nm to 70 Nm (44.25 to 51.63 lbf-ft) Plug (8).................................................................................................................. 40 Nm to 50 Nm (29.50 to 36.88 lbf-ft)
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-3
CUSHION CONTROL VALVE Description Identifying the ports
10 11 12 13 9
8
7
6
1 2 3 4 5 6 7 8 9
CONTROL VALVE HOUSING SPRING SPOOL SPRING SPOOL GUIDE O-RING FLOW RESTRICTION ADAPTATER PLUNGER ASSEMBLY O-RING
4
3 15
2
16
14
5
1
17
10 11 12 13 14 15 16 17
SPRING SPRING GUIDE O-RING SPOOL PLUG SPOOL SPOOL SPOOL
NOTE: The cushion control valve can have a machined or moulded body. This manual deals with only the machined body.
Lep SM4608016-0EN
Issued 09-07
Lep SM4608016-0EN
CUSHION SWITCH
SOLENOID VALVE
OPEN
CLOSED
ARM
CONTROL VALVE
REMOTE
CUSHION VALVE
THROTTLE a
THROTTLE b
CONTROL VALVE
ARM
THROTTLE d
THROTTLE c
LINE FILTER
CONTROL VALVE
BOOM
DOWN
UP BOOM
CONTROL VALVE
REMOTE
PILOT GEAR PUMP
OIL TANK
HYDRAULIC
Copyright ©
8016-4
System drawing
Issued 09-07
Copyright © 8016-5
Changed over to "SOFT" Lever in Neutral (1) The heat oil separated from the oil cooler line enters the cushion valve Port R. (2) Then, the oil passes the reverse notch spool and goes through passages e and f. After passing the outer circumference of each cushion spool, the oil returns to the hydraulic oil tank via Port T of the cushion valve. REVERSE NOTCH SPOOL
THROTTE b THROTTE d
CUSHION SPOOL THROTTE a
Lep SM4608016-0EN
THROTTE c
CUSHION SPOOL
Issued 09-07
Copyright © 8016-6
Arm OUT, operating (1) Pilot pressure enters the cushion valve at Port A from the remote control valve. As this pilot pressure enters the left end of the cushion spool and the left end of the reverse notch spool, each spool moves to the right. (2) The pilot pressure in the cushion spool enters the chamber g via the spool opening. Then, the pressure passes the outer circumference of the reverse notch spool and goes into the control valve via Port C. (3) The pilot pressure return oil from the control valve passes the outer circumference of the reverse notch spool and goes into the chamber f via Port D. Then, the oil passes the outer circumference of the cushion spool and returns to the hydraulic oil tank through Port T. (4) At this time, as the reverse notch spool is switched over to the right, the passages e and f are closed to the heat oil at the Port R. Therefore, the oil passes passage h and enters the left end of the cushion spool. The heat oil passes the cushion spool throttles c and d and enters the remote control V via Port B. (The heat oil releases the remote control valve).
TO CONTROL VALVE
FROM CONTROL VALVE
TO HYDRAULIC TANK
FROM
TO
REMOTE CONTROL
REMOTE CONTROL
VALVE
VALVE
THROTTE c
THROTTE d CUSHION SPOOL
CUSHION SPOOL TO HYDRAULIC TANK
ARM OUT, OPERATING
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-7
Arm OUT, stopped 1) As the pilot pressure from the remote control valve stops, the reverse notch spool returns to the neutral position. 2) The cushion spool also returns to the neutral position and the pilot return oil from the control valve passes the throttles a and b. Due to the differential pressure between the front and back of trottle, the cushion spool is moved to the left and as a result, the pilot return oil is restricted by trottle a. 3) Due to this restricting effect, the spool of the main control valve returns gradually to the neutral position. FROM CONTROL VALVE
TO REMOTE CONTROL VALVE
THROTTE b
THROTTE a
CUSHION SPOOL
Arm OUT, stopped
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-8
Changed over to "HARD" When the cushion switch is changed over to "HARD" position, the solenoid valve is changed over. The pilot pressure (3.92 MPa) from the gear pump enters the cushion valve at Port S. All the cushion spools (for booms and arms, 4 positions in total) are forcedly changed over to the inside. FROM CONTROL VALVE
FROM CONTROL VALVE
REVERSE NOTCH SPOOL
FROM REMOTE CONTROL VALVE
FROM SOLENOID VALVE
CUSHION SPOOL
ARM IN, STOPPED
CUSHION SPOOL
As the cushion spools are forcedly pushed down, when the arm is OUT, both in operation and not in operation, the pilot pressure goes through the inside of the cushion valve without passing the throttle. The heat oil from Port R returns to the hydraulic oil tank via Port T when the lever is in neutral. While the lever is being moved, the oil flows to the remote control valve.
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-9
Disassembly
STEP 4
NOTE: The numbers within brackets in the following steps refer to the schematic on page 3.
STEP 1
10 13
7
7
JD00552A
Remove the spool (13) and the spring (10) from the control valve.
STEP 5 JD00549A
If the cushion control valve has to be replaced, remove the adaptors and elbow unions and install them on the new control valve. Do not remove the four flow restriction adapters (7) installed in the sides of the valve. NOTE: Mark parts to ensure correct assembly in same valve bore as removed from.
11
13
STEP 2 10 9 JD00553A
8
NOTE: Removal to be carried out in case of a leak between the spool (13) and the spring guide (11). Put the spool (13) in a vice using wooden shims to protect the spool. Remove the spring guide (11) from the spool (13).
JD00550A
Remove the plug (8) with the O-ring (9) and the spring (10).
STEP 3
10 8
9
JD00551A
Remove the spring (10) and the O-ring (9) from the plug (8). Scrap the O-ring.
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-10
STEP 6
STEP 10
11 12 4
JD00554A
Remove the O-ring (12) from the spring guide (11). Scrap the O-ring.
JD00557A
Remove the spring (4).
STEP 11
STEP 7 Repeat steps 2 through 6 for the other spool.
3
STEP 8 5 A
6 2 7
JD00555A
Remove the flow restriction adaptor (7) and the O-ring (6).
JD00558A
Install an M4 cap screw (A) in the tapped hole of the spool (3). Remove the spool (3) with the spacer (5) and the spring (2). Remove the M4 cap screw.
STEP 12 3
STEP 9
2
6
5 7 JD00559A
Remove the spring (2) and the spacer (5) from the spool (3). JD00556A
Remove and discard the O-ring (6) and the flow restriction adaptor (7).
Lep SM4608016-0EN
STEP 13 Repeat steps 9 through 12 for the remaining three spools.
Issued 09-07
Copyright © 8016-11
Inspection
Assembly
STEP 1
NOTE: The numbers within brackets in the following steps refer to the schematic on page 3.
Clean all parts using suitable cleaning solvent. Immerse valve housing in cleaning solvent for several minutes to dissolve dirt or other foreign matter inside valve housing. Use low pressure compressed air to blow out any foreign matter from interior of valve housing. Dry parts using clean cloths.
NOTE: Lubricate all parts with clean hydraulic oil. Ensure that parts are assembled in the same groove as they were removed from.
STEP 1
STEP 2
3
Inspect springs for cracks, distortion, or evidence of permanent set. Replace a spring if any of these defects are observed.
STEP 3 Check the spools for cracks, holes, distortion or other damage. Check that the spools slide easily in the groove of the control valve housing. If any defects are observed replace the cushion valve.
5
STEP 4 JD00559A
Check the plugs, flow restriction adapters, and spring guides for damaged threads. Check the ports in flow restriction adapters for foreign matter, chipping, or other damage. Check spring guides for bent condition. Replace a defective part.
Install the spacer (5) on the spool (3).
STEP 2
STEP 5 Check the spacer for chipping, wear and signs of damage. If any of these conditions are seen replace the spacer.
2
STEP 6 Check for damaged threads and signs of internal wear on the control valve housing. If any defects are seen, replace the cushion valve.
3 5 JD00560A
Install the spring (2), the spool (3) and the spacer (5) in the control valve housing.
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-12
STEP 3
STEP 7 11 3 4
13
JD00561A
Install the spring (4) in the spool (3).
JD00563A
Place the spool (13) in a vice using wooden shims to protect it and tighten the spring guide (11).
STEP 4
STEP 8 10 11 6
13 7
JD00562A
Install a new O-ring (6) on the flow restriction adaptor (7). Install the flow restriction adaptor in the control valve housing.
Install the spring (10), the spring guide (11) and the spool (13) in the groove of the control valve housing.
STEP 5
STEP 9
JD00564A
Repeat steps 1 through 4 for remaining three spools.
10
STEP 6 11
12 13 JD00565A
Install the spring (10). JD00554A
Install the spring guide (11) using a new O-ring (12) on the spool (13).
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-13
STEP 10 9 8
JD00566A
Install a new O-ring (9) on the plug (8). Install the plug and O-ring in the housing.
STEP 11 Repeat steps 6 through 10 for the other spool.
STEP 12
JD00549A
If removed, install the adapters and elbows on the control valve.
Lep SM4608016-0EN
Issued 09-07
Copyright © 8016-14
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... Lep SM4608016-0EN
Issued 09-07
Copyright ©
Section 8017
8017
SAFETY VALVES
CNH
Lep SM4608017-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8017-2
TABLE OF CONTENTS BOOM SAFETY VALVE ................................................................................................................................................. 3 Identifying the ports .................................................................................................................................................... 3 Removal ..................................................................................................................................................................... 3 Installation .................................................................................................................................................................. 3 Disassembly ............................................................................................................................................................... 4 Assembly ................................................................................................................................................................... 6 DIPPER RELIEF VALVE ................................................................................................................................................ 8 Identifying the ports .................................................................................................................................................... 8 Removal ..................................................................................................................................................................... 8 Installation .................................................................................................................................................................. 8 Disassembly ............................................................................................................................................................... 9 Assembly ................................................................................................................................................................. 11
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-3
BOOM SAFETY VALVE Installation
Identifying the ports 2 3
When installing, use the same procedure in the reverse order of removal by assembling new seal rings.
1
For valve adjustment, see Section 8001.
4
5
6 CD02C001
1 2 3 4 5 6
PILOT SPOOL LEAK RETURN HIGH PRESSURE CIRCUIT BYPASS TOWARDS THE OTHER VALVE VALVE POWER SUPPLY SCREW SAFETY VALVE
Removal NOTE: Before performing any operation on the machine, carry out the following operations in the order shown. - Park the machine on hard, flat ground. - Lower the attachment to the ground. - Shut down the engine. - Release pressure in the hydraulic circuit (see Section 8000). Remove the hoses (1), (2) and (3) and plug the unions and the hoses. Remove the tube (4) and plug the ports. Remove the screws (5) and the relief valve (6). Plug the cylinder port.
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-4
Disassembly 13
16
12
17
14
18 19
15
11
6 7 1
2 10 9 Remove the spool stop cap (1) and discard the seal (2). Remove the screws (3), then the cover (4), discard the seal (5) and remove the springs (6) and (7). Remove the washer (8) and the spring seat (9). Remove the spool (10).
Lep SM4608017-0EN
8
5
3
4 CS02J542
Remove the plug (12), discard the seal (16), remove the spring (14) and the check valve (15) and mark their positions. Remove the plug (16), discard the seal (17), remove the spring (18) and the check valve (19) by marking their positions. Remove the valve (11).
Issued 09-07
Copyright © 8017-5
17
12
7
8
11
4
16
2 1
15
14
13
9
3 10
5
6
CS02J543
Remove the plug (1), the setting screw (2) and discard the seal (3). Remove the spring (4) and the check valve (5). Remove the body (6) and discard the seal (7). Remove the spring seat (8), discard the seal (9) and the back up ring (10). Remove the spring (11). Extract the check valve (12) from the sleeve (15), discard the seal (13) and the back up ring (14). Discard the seal (16) and the back up ring (17) from the sleeve (15).
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-6
Assembly
8
17
7 4 2
16
12 11 1
15
14
3 13
9
10
5
6
CS02J543
NOTE: When assembling, install new seal rings. Install a seal (16) and a back up ring (17) on the sleeve (15). Install a seal (13) and a back up ring (14) on the check valve (12). Lubricate and install the check valve (12) in the sleeve (15). Install the spring (11). Install a seal (9) and a back up ring (10) on the spring seat (8). Install the spring seat (8) taking care not to damage the seal (9) and the back up ring (10).
Lep SM4608017-0EN
Install a seal (7) on the body (6). Lubricate the body (6) and the inside of the spring seat (8). Put the body (6) in place. Install the check valve (5) and the spring (4). Install a seal (3) on the screw (2). Install the screw (2) without tightening it too much, the final tightening will be done with pressure setting. Install the blank nut (1).
Issued 09-07
Copyright © 8017-7
13
12
16
17
18 19
14 15
11 6 7
1
2 4 10
9
3 8
5 CS02J542
Install an O-ring (2) on the spool stop cap (1). Install the cap (1) on the relief valve. Lubricate and install the spool (10). Install the washer (8) and the spring seat (9). Install the springs (6) and (7) in the cover (4). Install an O-ring (5) on the cover (4). Install the cover (4) using screws (3). Install the valve (11).
Lep SM4608017-0EN
NOTE: Take care in respecting the position of each check valve assembly marked during disassembly. Install an O-ring (17) on the plug (16). Lubricate and install the check valve (19) and the spring (18). Install and tighten the plug (16). Install an O-ring (13) on the plug (12). Lubricate and install the check valve (15) and the spring (14). Install and tighten the plug (12).
Issued 09-07
Copyright © 8017-8
DIPPER RELIEF VALVE Identifying the ports
Installation When installing, use the same procedure in the reverse order of removal, by assembling new seal rings.
2
For valve adjustment, see Section 8001.
3 1 4 5 6
1 2 3 4 5 6
PILOT SPOOL VALVE POWER SUPPLY SPOOL LEAK RETURN VALVE LEAK RETURN SCREW RELIEF VALVE
Removal NOTE: Before performing any operation on the machine, carry out the following operations in the order shown. - Park the machine on hard, flat ground. - Lower the attachment to the ground. - Shut down the engine. - Depressurise the hydraulic circuit (see Section 8000). Remove the hoses (1), (3) and (4) and plug the unions and the hoses. Remove the tube (2), plug the tube and the union. Remove the screws (5) and the relief valve (6). Plug the cylinder port.
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-9
Disassembly 1
3
8
6
7
2 9
4
21
10
5 16
17
11
14 12 20
19 18 15
13 CS02J541
Remove the screws (1) and the cover (2), discard the seal (3). Remove the spring (4) and the check valve (5) after marking their positions. Remove the screws (6) and the cover (7), discard the seal (8). Remove the spring (9) and the check valve (10) after marking their positions. Remove the retaining screws from the spool stop cap (11), remove it and discard the seal (12). Remove the screws (13) and remove the cover (14), discard the seal (15). Remove the springs (16) and (17). Remove the seats from the spring (18) and (19). Remove the spool (20). Remove the valve (21).
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-10
16
17
12
7
8
11
4 2 1
13
15
3 14
9
10
5
6
CS02J543
Remove the plug (1), the setting screw (2) and discard the seal (3). Remove the spring (4) and the check valve (5). Remove the body (6) and discard the seal (7). Remove the spring seat (8), discard the seal (9) and the back up ring (10). Remove the spring (11). Extract the check valve (12) from the sleeve (13), discard the seal (14) and the back up ring (15). Discard the seal (16) and the back up ring (17) from the sleeve (13).
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-11
Assembly
17
7
8
11
12
4 2
16
1
13
3
15 14
9
10
5
6
CS02J543
NOTE: When assembling, install new seal rings. Install a seal (16) and a back up ring (17) on the sleeve (13). Install a seal (14) and a back up ring (15) on the check valve (12). Lubricate and install the check valve (12) in the sleeve (13). Install the spring (11). Install a seal (9) and a back up ring (10) on the spring seat (8). Install the spring seat (8) taking care not to damage the seal (9) or the back up ring (10). Lubricate the body (6) and the inside of the spring seat (8). Put the body (6) in place. Install the check valve (5) and the spring (4). Install a seal (3) on the screw (2). Install the screw (2) without tightening it too much, the final tightening will be done with pressure setting. Install the blank nut (1). Install a seal (7) on the body (6).
Lep SM4608017-0EN
Issued 09-07
Copyright © 8017-12
1
3
8
2
6
7 10
9
4 21
5
16
17
11
14 12
20 19 18 15
13 CS02J541
Install the valve (21). Lubricate and install the check valve (5) and the spring (4) according to the marks made during disassembly, install the cover (2) equipped with a seal (3). Install the screws (1). Lubricate and install the check valve (10) and the spring (9) according to the marks made during disassembly, install the cover (7) equipped with a seal (8). Install the screws (6). Install a seal (12) on the spool stop cap (11). Install the retaining screws. Lubricate and install the spool (20). Install the spring seats (18) and (19). Install the springs (16) and (17). Install a seal (15) on the cover (14). Install and fasten the cover (14) using screws (13).
Lep SM4608017-0EN
Issued 09-07
Copyright ©
Section 8018 DISASSEMBLY AND REASSEMBLY
8018
OF THE HYDRAULIC SWIVEL
CNH
Lep SM4608018-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8018-2
TABLE OF CONTENTS SPECIAL TORQUE .........................................................................................................................................................2 SPECIAL TOOLS ............................................................................................................................................................3 HYDRAULIC SWIVEL .....................................................................................................................................................4 Description ..................................................................................................................................................................4 Disassembly ...............................................................................................................................................................5 Assembly ....................................................................................................................................................................7
SPECIAL TORQUE Cover retaining screws (7) ....................................................................................62.7 to 72.5 Nm (46.24 to 53.47 lbf-ft) Thrust plate retaining screws (9)...........................................................................31.4 to 37.3 Nm (23.16 to 27.51 lbf-ft)
Lep SM4608018-0EN
Issued 09-07
Copyright © 8018-3
SPECIAL TOOLS Jig for pushing out axle
M16-M20 FULLY THREADED BOLT
F SCREW M16-M20 FEMALE
G B A
D COVER (6) FITTING SIZE
E
Lep SM4608018-0EN
C
A
30 - 40 mm (1.18 - 1.57 in)
E
20 mm (0.79 in)
B
20 mm (0.79 in)
F
350 - 400 mm (13.78 - 15.75 in)
C
20 mm (0.79 in)
G
7 x 25 mm (0.27 x 0.98 in)
D
5 mm (0.197 in)
Issued 09-07
Copyright © 8018-4
HYDRAULIC SWIVEL Description
1 2 3 4 5 6
PIVOT "V" SEAL O-RING PAKING RING ROTOR COVER
7 8 9 10 11
SCREW * LOCTITE SCREW * THRUST PLATE O-RING
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Lep SM4608018-0EN
Issued 09-07
Copyright © 8018-5 NOTE: For removing the hydraulic swivel, refer to Section 8006.
STEP 3
Disassembly Always handle the components carefully. Never force, hit or drop components. Avoid any contamination by dust, water or foreign bodies. Work in a clean area with clean tools. Always remove the pivot (inner component) and the bushing (outer component) using a press.
STEP 1
Remove the screws (9) and the thrust plate (10).
STEP 4
Remove the screws (7) and the cover (6).
STEP 2
Push out the axle (1) from the rotor (5) using a jig.
STEP 5
Remove and discard the O-ring (11).
Remove the "V" seal (2) from the pivot (inner component) (1) and discard it.
Lep SM4608018-0EN
Issued 09-07
Copyright © 8018-6
STEP 6
Remove the O-ring (3) and the sealing rings (4) from inside the bushing (outer component) (5). Discard the sealing rings and the O-ring.
Lep SM4608018-0EN
Issued 09-07
Copyright © 8018-7
Assembly
STEP 3
Clean all the components. Polish any scratches or rough areas with an oil stone. Use seals, O-rings and new sealing rings. Take the same precautions as during removal.
STEP 1
Check the proper installation of the O-ring and the sealing rings using a mirror. Apply hydraulic fluid, make sure that the components are not protruding, twisted, etc. Clean the bushing (outer component) with a cleaning solvent or low pressure compressed air.
STEP 2
Set one packing rings (4) in each groove up to the second from the top. Set the O-ring (3) in the top groove.
Lep SM4608018-0EN
Issued 09-07
Copyright © 8018-8
STEP 4
STEP 7
Install a new "V" seal (2) on the pivot (inner component) (1) and coat it with clean hydraulic oil.
Install the O-ring (11).
STEP 8
STEP 5
Insert the pivot (inner component) (1) in the bushing (outer component) (5).
Install the cover (6) and the screws (7). Tighten the screws to torque (see page 2).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
Install the thrust plate (10) and the screws (9).
Lep SM4608018-0EN
Issued 09-07
Copyright ©
Section 8019
8019
DISASSEMBLY AND REASSEMBLY OF THE SWING HYDRAULIC MOTOR
CNH
Lep SM4608019-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8019-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 3 TORQUE SETTINGS ...................................................................................................................................................... 3 SPECIAL TOOLS ............................................................................................................................................................ 3 HYDRAULIC SWING MOTOR ........................................................................................................................................ 4 Description .................................................................................................................................................................. 4 Disassembly................................................................................................................................................................ 6 Inspection.................................................................................................................................................................... 9 Maintenance Reference Table .................................................................................................................................. 10 Assembly .................................................................................................................................................................. 11 TROUBLESHOOTING .................................................................................................................................................. 17 SECONDARY RELIEF .................................................................................................................................................. 20 Description ................................................................................................................................................................ 20 Disassembly.............................................................................................................................................................. 21 Inspection.................................................................................................................................................................. 21 Assembly .................................................................................................................................................................. 21
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-3
SPECIFICATIONS See Section 1002.
TORQUE SETTINGS Bypass valve plug (27)........................................................................................................................ 78 Nm (57.53 lbf-ft) Non return check valve plug (52) .................................................................................................... 137 Nm (101.04 lbf-ft) Cover screw (49) and (56) .............................................................................................................. 157 Nm (115.79 lbf-ft) Safety valve (48) ............................................................................................................................. 137 Nm (101.04 lbf-ft)
SPECIAL TOOLS
A
C
B
A
E
B
C D
Press fitting jig for inner ring (2) and taper roller bearing (4) A Ø 60 mm C 130 mm B Ø 55.2 ±0.1 mm D 140 mm E 15°
A
B
Installation jig for brake piston (12) A Ø 190 mm C 50 mm B Ø 220 mm
C G H
D E
A B C D
F
Installation jig for oil seal (3) Ø 100 mm E 20 mm Ø 81 mm F 155 mm Ø 60 ±02 mm G 30° 50 - 01 mm H 3 mm
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-4
HYDRAULIC SWING MOTOR Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 A B
SLEEVE SNAP RING OIL SEAL BEARING RETAINING WASHER PISTON FACE THRUST PLATE PISTON ASSEMBLY FRICTION DISK STEEL DISK O-RING BRAKE PISTON O-RING SPRING COVER O-RING PLUG PISTON SPRING WASHER TEFLON SEAL BUSHING DISTRIBUTION PLATE BEARING CYLINDER HOUSING SPRING BYPASS VALVE PLUG CHECK VALVE SPRING O-RING BACKUP RING NON-RETURN CHECK VALVE SPRING SEAT CHECK VALVE SEAT CHECK VALVE SPRING O-RING SHIM VALVE HOUSING PISTON O-RING O-RING BACKUP RING PLUG SLEEVE LINER NUT SECONDARY RELIEF ASSEMBLY SCREW BACKUP RING O-RING NON-RETURN CHECK VALVE PLUG SNAP RING RETAINING PIN RETAINING PIN SCREW SHOE BRAKE PILOT PORT
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-5
37
49
31 33
30
32
31
30
48 47 29
41
28
46
27
45 44
42 43 40 39 38 36 35 34 26 19
21 20
52 15
51 18
17
50 16
54
14
55
13
22
12
B
11
23
10 9
53
8
24
7
25
A 6
5
4
3
2
1 CS02J563
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-6
Disassembly STEP 1
STEP 3 48
56
48
49
52 15 26
33 27
D
C
Remove the oil level dipstick (C) and dipstick tube (D). Remove relief valve assemblies (48) from swing motor. Remove the by-pass valve assemblies (27), as well as the plugs (52), the springs (26) and the non-return check valves (33). Remove and discard all the O-rings of each component.
STEP 2
Remove the retaining screws (49) and (56). Remove the cover (15) from the motor housing.
STEP 4 53 23
A
22 18 15
CS02C520
Place the cover with the shaft on top and remove the retaining ring (53) from the shaft. Remove the needle bearing (23) and the distribution plate (22). Remove the pistons (18) from the distribution plate (22).
To facilitate assembly, put alignment marks (A) on the cover and motor housing.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-7
STEP 5
STEP 8 NOTE: Protect the housing and the piston surfaces with rags when you lever the piston out of the housing.
13
13
12
15 A
A 12
CS02C521
13
Remove and discard the large O-ring (13) from the cover (15).
25
STEP 6 21 20 19
Install two M6 screws (A) in tapped holes of the brake piston (12). Lever these screws and free the brake piston (12) from the housing. Remove and discard the O-ring (13) from the housing (25) and the brake piston (12). Remove the two M16 screws (A) from the brake piston.
15
CS02C522
Remove the bushings (21), the Teflon rings (20) and the washers (19) from the cover (15).
STEP 9 10
STEP 7 14 25 9
25
Remove the springs (14) from the brake piston (12). Remove the four friction plates (9) and the four disc plates (10) from the swing motor housing (25).
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-8
STEP 10
STEP 12
2
24
1 4
25
CS02C528
Remove the retaining ring (2) from the fluted shaft. Remove the conical roller bearings and the sleeve (1) using an antisticking pin puller. Remove the cylinder assembly (24) from the motor housing (25).
STEP 11
STEP 13 NOTE: Mark the location of the pistons on the base plate and on the cylinder. Pistons must be installed in same positions during assembly.
4 3
6 7
3
8
24
Remove the bearing (4) from the motor housing. Position the motor housing in a press. Using a suitable sleeve or a centring piece, drive the spy joint (3) out from the housing. Scrap the spy joint (3). Remove the piston plate (6), the piston assembly (8) and the base plate (7) from the cylinder (24).
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-9
Inspection
STEP 14
STEP 1
6
7
Check the distribution plate sliding surfaces for signs of seizing or wear. If there is evidence of seizing or wear, the plate should be replaced.
STEP 2 Check for wear of the pistons. Replace the motor if the depth of any shoe sliding surface is less than 0.45 mm, if the shoe surfaces are seriously damaged or if a piston assembly shows any sign of seizing. There should be no wear of the external surfaces of the piston assemblies.
8
CS02C530
Slip the piston plate (6) out of the sliding surfaces of the piston assemblies (8), while ensuring that it does not get damaged. Remove the pistons from the base plate (7).
STEP 15
STEP 3 Check for signs of seizing or wear on the piston plate sliding surface. The plate should be replaced if there is evidence of seizing or wear.
STEP 4 Check for signs of seizing, wear or damage on the cylinder piston bores. The motor should be replaced if there is evidence of seizing or if the piston bores are damaged.
5
Inspect the needle bearing and tapered roller bearing for damage. The bearings should be replaced if any damage is found, or after 3000 hours of operation.
24
CS02C531
Remove the backup washer (5) from the fluted shaft.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-10
Maintenance Reference Table Table 1 Part name
Locations to be inspected and measured
Reference valves (tolerance limits)
Measuring instruments
Instructions for repair and remedies
Piston assembly (8)
Roughness on shoe sliding face
0.8 S
Surface roughness gauge
Repair with paper lap.
Groove depth in 0.45 mm or more shoe sliding section
Micrometer
Replace with new ones.
Looseness on the ball joint section be0.4 mm or less tween piston and shoe
Dial gauge
Replace with new ones.
Piston face (7) Cylinder (24)
Distribution plate (22) Piston assembly (8) Cylinder (24)
Piston diameter
Almost no wear. If scratches or seizure are found, replace with new ones.
Surface roughness
0.8 S
Surface roughness gauge
Lap
Roughness on the edge
0.4 S
Surface roughness gauge
Lap
Piston hole
Almost no wear. If scratches or seizure are found, replace the motor.
Surface roughness
0.8 S
Clearance between piston diameter and 0.04 mm or less cylinder bore
Surface roughness gauge
Lap
Micrometer Air micrometer
Motor replacement
Table 2 Part name
Inspection and Maintenance Reference
Taper roller bearing (4) Needle bearing (23)
Replace bearings with new ones every 3,000 hours even if they function normally. Additionally, always replace bearings when reassembling, even if it's within 3,000 hours.
Spy joint (3)
If damage is found on the lip, replace it with a new one. Additionally, replace seals with new ones every 3,000 hours even if they function normally with no leaking. Additionally, always replace seals when reassembling, even if it's within 3,000 hours.
O-rings (11), (13), (16), (30), If damage is found on O-ring, replace it with a new one. Additionally, replace rings with new ones every 3,000 hours even if they function (37), (41), (42) and (51) normally with no leaking. Additionally, always replace rings when reassembling, even if it's within 3,000 hours.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-11
Assembly STEP 1
STEP 3 7
5
8
SPHERICAL
24 24
CS02C532
Apply grease (No. 2 EP lithium grease) on the spherical portion of the cylinder shaft that is in contact with the retaining washer (5) and install the retaining washer (5).
STEP 2
CS02C534
Apply clean hydraulic fluid on the cylinder (24) bores. Install the piston assemblies (8) and the thrust plate (7) in the barrel (24). Be sure that the pistons are installed in the same bores as they were removed from.
STEP 4 8 6 7 A
CS02C533
24
Apply clean hydraulic fluid on the sliding surface of the piston assemblies (8). Install the piston assemblies (8) in the ports of the base plate (7). CS02C535
Apply clean hydraulic fluid on the sliding surfaces of the piston assemblies (A) and install the piston plate (6).
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-12
STEP 5
STEP 7 PRESS-FITTING JIG
A 4 (INNER)
3
24
CS02C536
Install a new taper roller bearing inner cage (4) on the barrel shaft (9).
STEP 6 PRESS-FITTING JIG
1
Before installation, apply grease on the lip of the oil seal (3). Position housing in a press. Apply Loctite 504 to the periphery of the lip seal. Install and centre the oil seal (3) in the bore of the housing. With a suitable sleeve (A), fit the oil seal (3) in the bore of the housing. NOTE: Pay attention to the fitting directions of the oil seal (3).
2 LOCTITE APPLIED
TAPER ROLLER BEARING SIDE
4 CYLINDER OUTPUT SHAFT SIDE
24
STEP 8 4 (OUTER RING) CS02C537
Apply a thin coat of Loctite 515 or 518 where the sleeve (1) is installed on the cylinder shaft. Fit the sleeve (1) on the shaft and install the snap ring (2).
25
Install a new bearing outer cage (4) in the housing (25).
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-13
STEP 9
STEP 11 CYLINDER END FACE
13 24
12 11
HOUSING END FACE
25
25 Apply grease on the new O-rings (11) and (13); install the O-ring (11) in the housing (25) and the O-ring (13) on the brake piston (12).
STEP 12 A
B
(B) 40 to 50 mm (1.57 in to 1.96 in) Install the housing (25) on shims (A). Carefully install the barrel assembly (24) in the housing (25). Be careful when installing the cylinder assembly not to damage the splines on the shaft.
STEP 10
REINFORCING JIG
12
25 10
9
Apply clean hydraulic fluid on the periphery of the brake piston (12). Push the brake piston (12) into the housing (25).
25
Apply clean hydraulic fluid to both faces of the friction disks (9) and the steel disks (10). First, install a steel disk then a friction disk, then a steel disk, a friction disk, then a steel disk, a friction disk, finally the last steel disk and the last friction disk. Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-14
STEP 13 PORTS A AND B SIDE V SHAPED GROOVE
14
25
ROUND SHAPED GROOVE RELIEF SIDE
STEP 15 53 Install the springs (14) in the brake piston (12) in their original locations.
23
STEP 14 22 18 21
15
20 19 54
J7CB20C-26
Install the new needle bearing inner race (23) on the shaft and install the retaining ring (53).
STEP 16 13
15 J7CB20C-28
Install the spring washers (19) in the cover (15). Apply No. 2 EP lithium grease on the bushings (21), the new Teflon rings (20) and in the cover (15). Install a Teflon ring on each of the bushings. Install the bushings with seals in their holes in the cover. Apply No. 2 EP lithium grease on the pistons and install the pistons (18) in the distribution plate (22). Be sure that the pistons are installed in same bore as they were removed from. Install the pistons and the distribution plate (22) on the cover (15), positioning the plate hole on the stop dowel (54).
15 J7CB20C-30
Install a new, greased O-ring (13) on the cover (15).
NOTE: Pay attention to the installation directions for the distribution plate (22) on the cover (24), which were marked before disassembly.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-15
STEP 17
STEP 19 56
25
49
15
25
LOCTITE 504
Apply Loctite 504 to the mating surfaces of the motor housing (25) and the cover (15).
STEP 18
Install the retaining screws (49), (56) and tighten to a torque of 157 Nm.
STEP 20 48
15
48
52 55 26
26
25 33 27
D Carefully install the cover (15) and the distribution plate (22) on the housing, making sure that the distribution plate and bushings do not fall off the cover. Align the motor and cover marks, engage the stop dowel (55) in the brake piston orifice (12).
Lep SM4608019-0EN
C
Install the oil level dipstick (C) and dipstick tube (D). Install the relief valve assemblies (48) on the swing motor. Install the by-pass valve assemblies (27) and the plugs (52), the springs (26) and the non-return check valves (33). Install new O-rings on each component.
Issued 09-07
Copyright © 8019-16
STEP 21 PORT P
15
25
Open the entry and exit ports and apply pilot pressure of 2.9 to 4.9 MPa to the brake relief port. Then make sure that the output shaft can be smoothly rotated, one turn or more, with torque of 30 to 40 Nm If it does not rotate properly, it is suspected that assembly is not completed correctly. Disassemble once again and readjust it. Make sure that drain port is released. NOTE: Ensure that the set pressure on the relief valve (48) indicates a normal pressure after the hydraulic motor is installed onto this machine.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-17
TROUBLESHOOTING Described below are measures to be taken when any abnormalities or malfunctions are found while the hydraulic motor is used. Details on disassembling/inspection and reassembling are also described later but careful handling is absolutely needed to avoid any damage to the sliding parts of the motor while conducting these procedures.
Table 1 Symptom
Cause
Exterior inspection
Does not Motor's internal Measure drain output. rotate breakage
Motor's internal Open the inlet and outlet breakage ports on the motor and apply pilot pressure of 2.9 to 4.9 MPa to the brake relief port. Then attempt to rotate the output shaft with torque of 30 to 40 Nm.
Remedy
Repairs
If motor supply input is equal See Table 2. to the drain output, there is high possibility of breakage in sliding section. Disassembling/inspection is required. If the output shaft does not Replace damrotate smoothly with the aged parts or torque stated to the left, motor assembly. there is high possibility of internal breakage. Disassembling/inspection is required.
Incorrect settings Measure load pressure with Reset to specified set presat relief valve in pressure gauge. sure. the circuit Excessive slippage
Wear or damage Measure drain output. in the sliding part of the motor and in the high pressure seal section
If the drain output is more See Table 2. than 2.5 L / min., the leakage is too high. Disassembling/ inspection is required.
Oil temperature is Measure oil temperature. too high and there is excessive internal leakage inside the motor
Lower the oil temperature.
Lack torque
of Wear or seizure of the motor sliding section Abnormal noises
Open the inlet and outlet ports on the motor and apply pilot pressure of 2.9 to 4.9 MPa to the brake relief port. Then attempt to rotate the output shaft with a torque of approx. 30 to 40 N•m.
If the output shaft does not rotate smoothly with the torque stated to the left, there is high possibility of internal breakage. Disassembling/inspection is required.
Inspect parts (a) to (e) listed in Table 2, and also the bearings. Change them if any abnormality is found.
Incorrect settings Measure load pressure with Reset to specified set presat relief valve in pressure gauge. sure. the circuit
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-18 Symptom
Cause
Exterior inspection
Lack torque
of Motor's internal Check whether there are any breakage foreign metal substances in the motor oil drain and drain Abnormal filters. noises (cont.)
Remedy
Repairs
If any foreign metal substances are found, there is high possibility of motor's internal breakage. Disassembling/inspection is required.
Repair or replace damaged parts. Motor assembly replacement.
A lot of air is Check the oil in the tank and Bleed air completely. mixed in the oil motor case. Looseness on Looseness on piping fix- Fasten them with proper tightening sections tures. tightening torque. Check for looseness on the fixture mounting bolts, motor mounting bolts and bolts on the motor. Abnormal heat
Seizure of motor's Check for foreign metal subsliding and rotat- stances in the motor oil drain and drain filters. Apply pilot ing sections pressure of 2.9 to 4.9 MPa to the brake relief port and attempt to rotate the output shaft with torque of 30 to 40 Nm.
If any foreign metal substances are found or the output shaft does not rotate smoothly with the torque above, there is a high possibility of internal breakage. Disassembling/inspection is required.
Oil leak- O-ring is damage from aged. mating Oil seal surface is faces damaged. Loose bolts Oil leak- Wear or damage age from on the lips of oil seal oil seal. Wear or damage on seal sections of shaft
Repair or replace damaged parts. Motor assembly replacement.
Replace O-rings. Repair or replace seal surfaces. Check for loose bolts.
Fasten them with proper tightening torque. Replace oil seal.
Repair or replace motor assembly.
Abnormal pres- Check the internal pressure Internal pressure in the case Replace oil seal. and drain output in the case. should be 0.3 MPa or less. sure in the case Repair or replace If drain output is too large, damaged parts. disassembly/inspection is Motor assembly required. replacement.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-19
Table 2 Letter
Parts to be inspected
Repairs
a
Wear in the sliding part of the distribution plate (22)
Repair or replace parts.
b
Damage in the sliding section of the piston plate (6)
Repair parts or replace the motor.
c
Damage in the sliding section of the piston assembly (8)
Repair parts or replace the motor.
d
Wear in piston outer diameter of the piston assembly (8)
Repair parts or replace the motor.
e
Wear in piston hole of the cylinder (24)
Replace motor.
f
Damage in Teflon ring (20)
Replace parts.
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-20
SECONDARY RELIEF Description 38
41
47
40
44
34
35
36
37
39
45
46
43
42 CS02C552
34 35 36 37 38 39 40
SPRING SEAT CHECK VALVE SPRING O-RING SHIM VALVE BODY PISTON
Lep SM4608019-0EN
41 42 43 44 45 46 47
O-RING BACK-UP RING O-RING PLUG SLEEVE LINER NUT
Issued 09-07
Copyright © 8019-21
Disassembly
Inspection
STEP 1
NOTE: Individual relief valve assembly parts cannot be replaced. If a relief valve assembly fails to operate properly for any reason other than dirt or foreign matter, the entire assembly must be replaced.
Remove the nut (47), the plug (44), discard the seal (43) and the back up ring (42).
STEP 2 Remove the sleeve (45) and the piston (40).
STEP 3 Remove the liner (46), the shim (38) and discard the O-ring (41).
STEP 4
Assembly NOTE: The numbers within brackets in the following steps refer to the schematic on page 15. NOTE: When installing, install new seal rings.
STEP 1 Install an O-ring (37) on the valve body (39).
Remove the spring (36), the check valve (35) and the spring seat (34).
STEP 2
STEP 5
Install the spring seat (34) in the valve body (39).
Remove and discard the O-ring from the valve body (39).
STEP 3 Oil the inside of the spring seat (34). Install the check valve (35) in the spring seat (34).
STEP 4 Install the spring (36) on the valve body (39).
STEP 5 Install an O-ring (41) on the liner (46). Install a shim (38) on the spring (36).
STEP 6 Install the liner (46) in the valve body (39), taking care not to damage the O-ring (41).
STEP 7 Install the piston (40) in the sleeve (45). Install the sleeve (45) in the liner (46).
STEP 8 Install a back up ring (42) and an O-ring (43) on the plug (44). Install the plug (44) in the liner (46).
STEP 9 Install the blank nut (47).
Lep SM4608019-0EN
Issued 09-07
Copyright © 8019-22
NOTES ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................
Lep SM4608019-0EN
Issued 09-07
Copyright ©
Section 8020
CNH
Lep SC4608020-0EN
Copyright © 2007 CNH France S.A. Printed in France March 2007
8020
HYDRAULIC FUNCTIONS
Copyright © 8020-2
TABLE OF CONTENTS HYDRAULIC FUNCTIONS...................................................................................................................................... 3 List of functions ................................................................................................................................................... 3 TRAVEL CIRCUITS ................................................................................................................................................ 6 1. High-speed Travel Circuit................................................................................................................................ 6 2. Low Speed Travel Circuit ................................................................................................................................ 8 3. Straight Travel Circuit.................................................................................................................................... 10 SWING CIRCUITS ................................................................................................................................................ 12 1. Swing Parking Circuit (Lever in Neutral / Swing Locked).............................................................................. 12 2. Swing Parking Circuit (Brake Released) ....................................................................................................... 14 3. Swing Push Digging ...................................................................................................................................... 16 ARM CIRCUITS .................................................................................................................................................... 18 1. Arm Out Circuit ............................................................................................................................................. 18 2. Arm-In Load Holding ..................................................................................................................................... 20 3. Arm-In Circuit ................................................................................................................................................ 22 BOOM CIRCUITS ................................................................................................................................................. 24 1. Boom-Up Circuit (Single) .............................................................................................................................. 24 2. Boom-Up Circuit (Combined) ........................................................................................................................ 26 3. Boom-Down Load Holding ............................................................................................................................ 28 4. Boom-Down Circuit ....................................................................................................................................... 30 BACKUP CIRCUITS.............................................................................................................................................. 32 1. Combined Circuit (Breaker Circuit) ............................................................................................................... 32 2. Combined Circuit (High Speed Confluence Circuit) ...................................................................................... 34
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-3
HYDRAULIC FUNCTIONS List of functions Functions
Description
Pages
Travel Circuits 1) High speeds can be achieved by setting the two-level inclinatory angle of the travel motor to the smaller angle side. High speed travel 2) Load pressure applied to the travel motor automatically changes the speed to circuit the lower speed. 3) Travel load pressure does not regulate the controller.
Page 6
Low speed travel circuit
Low speeds can be achieved by setting the two-level inclinatory angle of the travel motor to the larger angle side.
Page 8
Maintains machine's straight travel when attachment or swing operations are performed during its travel.
Page 10
Straight travel circuit
Swing Circuits 1) When the swing lever is in neutral, the swing parking is activated and the swing is fully held. 2) When the swing lever is operated, the parking brake is released by signals from the pressure switch. 3) When the swing lever is in neutral, the parking brake is released by load pressure generated by attachment operation. 4) The parking brake starts to operate 5 seconds after the swing lever comes in neutral and after the load pressure has become lower than the specified values. 5) When the swing lock switch is turned on, the parking brake starts to operate. At the same time, pilot pressure works on both ends of the swing spool.
Page 12
Swing push digging
When swing and arm operation are conducted simultaneously, swing pushing function can be obtained by the swing override (arm parallel tandem) throttle valve integrated in the control valve.
Page 16
Vibration swingback
The anti reverse valve attached to the swing motor reduces swingbacks that occur when the swing stops.
Swing parking circuit
-
Arm Circuits Arm-out circuit Arm-in load holding Arm-in circuit
Switching between arm (1) and (2) spools makes the hydraulic oil flows merge, achieving faster speed.
Page 18
Regeneration within the boom spool is used to increase speed and prevent cavitation.
Page 20
High pressure is suppressed with the bleed-off circuit and tilting is mitigated.
Page 22
Boom Circuits
Boom-up circuit
1) Switching between boom (1) and (2) spools makes hydraulic oil flows merge, achieving faster speed. 2) When the arm is operated with the boom simultaneously, the flow volume to the arm side is secured through the swing override (arm parallel tandem) variable throttle valve.
Boom-down load holding
1) The load holding valve that is integrated in the control valve reduces the natural drop of the boom. 2) Boom-down pilot pressure enables boom-down operation by releasing the load holding valve.
1) The regenerative circuit in the boom (1) spool works to improve the boom's speed. It also prevents negative pressure from occurring. 2) Boom (2) does not operate. Boom-down circuit 3) The bleed-off circuit in the spool reduces extra vibrations when the boom is lowered.
Lep SC4608020-0EN
Page 24
Page 28
Page 30
Issued 03-07
Copyright © 8020-4 Backup Circuits Combined circuit
1) Backup circuit section is provided at control valve. 2) Switching over the spool in the control valve initiates internal confluence.
Page 32
Others Cushion
A cushion valve with heat circuit is attached to the pilot line to reduce shocks when the arm or boom movement stops.
-
Auto power boost
Through the engine load ratio and circuit pressure, the main relief pressure will be raised from 31.4 MPa to 34.3 MPa.
-
This is designed to reduce power consumption by minimizing the flow of the discharge from the hydraulic pump when operating with no load.
-
Negative control
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-5
This page has been left blank intentionally
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-6
Travel Circuits 1. High-speed Travel Circuit With high speed travel, high speeds can be achieved by setting the two-level inclinatory angle of the travel motor to the smaller angle side. The circuit has a travel motor that automatically switches over to lower speed by utilizing load pressure on the travel motor when traveling at high speed. Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and left travel spools. By these flows, the machine travels forward and backward. By operating the travel mode switch, electric signals are sent to the controller, and from the controller, electric signals are sent to the solenoid valve for 2-speed (high speed) travel in the 6-way solenoid valve.
By the switchover of the solenoid valve, the original pilot pressure (3.9 MPa) from port C1 on the 6-way solenoid valve enters port P of right and left travel motors via the rotating joint to set the inclinatory angle of the travel motor to the smaller angle side, which enables high speeds.
pb6/B6. pa6/A6. pa1/A1. pb1/B1. 10. 15. 21. 25/26. 52. 108. A1. C1. S2. Y2. Y4.
RH forward travel RH reverse travel LH forward travel LH reverse travel Main hydraulic pump Main control valve Travel motors Boom cylinders 6 solenoid valve bank Straight travel valve Controller Travel 2nd speed pilot Travel mode switch Pilot pressure solenoid valve 2 stage travel solenoid valve
Legend
Pressure Line Pilot Pressure Line Drain line Tank line Pilot tank line Electric line
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-7
High Speed Travel Circuit
Boom cylinder T1
T2
26
P
21
VA
VB
VB
VA
pb6
21 Travel (Left)
pa6
B1 A1
pb1 pa1
Switch panel
S2
Travel (Right)
B6 A6
P
Travel motor
25
Straight travel valve 108
TRAVEL P
2-speed travel
T
Lever lock
P1
P2
Control valve
15
Y2
C1
A1
Controller P
Y4 A1
52
6-way solenoid valve
10
A2
A3
Hydraulic pump
330.1.03.03.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-8
2. Low Speed Travel Circuit The two-level inclinatory angle in the travel motor is set to the larger angle side. When the travel status is set to high speed and the key switch is turned off and turned on again, the speed setting will always return to low speed. Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and left travel spools. By these flows, the machine travels forward and backward. The solenoid valve for high speed travel is turned off and the oil in port P of the travel motor enters the tank line and establishes a connection. As a result, the inclinatory angle of the travel motor is set to the larger angle side.
pb6/B6. pa6/A6. pa1/A1. pb1/B1. 10. 15. 21. 25/26. 52. 108. A1. C1. S2. Y2. Y4.
RH forward travel RH reverse travel LH forward travel LH reverse travel Main hydraulic pump Main control valve Travel motors Boom cylinders 6 solenoid valve bank Straight travel valve Controller Travel 2nd speed pilot Travel mode switch Pilot pressure solenoid valve 2 stage travel solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-9
Low Speed Travel Circuit
Boom cylinder T1
T2
26
P
21
VA
VB
VB
VA
pb6
21 Travel (Left)
pa6
B1 A1
pb1 pa1
Switch panel
S2
Travel (Right)
B6 A6
P
Travel motor
25
Straight travel valve 108
TRAVEL P
2-speed travel
T
P1
Lever lock
P2
Control valve
15
Y2
C1
A1
Controller P
Y4 A1
52
6-way solenoid valve
10
A2
A3
Hydraulic pump
330.1.03.03.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-10
3. Straight Travel Circuit As an example, we describe the operation where travel and boom up are operated at the same time. The pilot oil pressure enters from port PP of the control valve and communicates with the tank side via passages of travel spool and spools for attachments (boom, arm, bucket and swing). When travel and boom-up operations are performed simultaneously, all circuits, which have been communicating with the tank, will be shut off by spools. This makes pilot pressure oil entered from the port PP to lose where to flow and original pressure (3.9 MPa) switches over the straight travel selector valve. The pressure works to the pilot chamber in straight travel valve allowing the valve to be switched over. As the result of the switchover of the straight travel valve, the pressurized oil in the control valve P1 drives the right and left travel motors and the pressurized oil in the control valve P2 drives the attachments. The right and left pressures become equal because one pump drives both the right and left motors. This realizes straight travel. Additionally, extra hydraulic oil from P2 is supplied via the check with travel confluence restriction to the travel side, and speed reduction is minimized. The same theory applies and the circuits operate the same way when upper actuators other than boom and travel are operated at the same time.
pb6/B6. pa6/A6. pb1/B1. pa1/A1. 10. 15. 21. 25/26. 52. 108. A1. C1. S2. Y2. Y4.
RH forward travel RH reverse travel LH forward travel LH reverse travel Main hydraulic pump Main control valve Travel motors Boom cylinders 6 Solenoid valve bank Straight travel valve Computer / Controller Travel 2nd speed pilot Travel mode switch Pilot pressure solenoid valve 2 stage travel solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-11
Straight Travel Circuit
Boom cylinder T1
T2
25
26
VA
VB
VB
VA
)
Pa3
P
A7 B7 pb7 pa7
Pb3
Travel motor
P
21
Travel (Left)
21
Travel (Right) pb6 pa6
B1 A1
pb1 pa1
Switch panel
B6 A6
Straight travel valve 108
TRAVEL
S2 P1
Lever lock
2-speed travel T
Y2
PP
P2
valve
15
C1 Controller
A1
P
Y4
A1
52
6-way solenoid valve
A2
A3
10 Hydraulic pump
330.1.03.03.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-12
Swing Circuits 1. Swing Parking Circuit (Lever in Neutral / Swing Locked) When the engine is started and the swing lever is in neutral, the swing brake solenoid valve becomes turned on (24 V input) and the swing parking brake is activated. When the swing lock switch is on, even if the swing pressure switch or attachment pressure switch is turned on, the swing lock switch overrides and the parking brake remains unreleased. Since pressure oil out of the port C5 of 6-way solenoid valve works on both sides of the swing spool while the swing is being locked, the spool in the control valve will not be switched over even if the swing control lever is engaged.
pb2/B2. pa2/A2. 10. 15. 22. 27. 54. 61. A1. B22. B26. B42. B44. C2. C5. S8. Y1. Y2. Y3.
LH swing RH swing Main hydraulic pump Main control valve Swing motor Arm cylinder Swing control valve 6 Solenoid valve bank Controller Swing pilot pressure switch Upper pilot pressure switch Pump pressure sensor P1 Pump pressure sensor P2 Swing brake pilot Swing shut-off pilot Swing brake switch Swing pilot shut-off solenoid valve Pilot pressure solenoid valve Swing brake solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-13
Swing parking circuit (Lever in neutral / Swing locked) Swing motor
22
27 Arm cylinder
P
)
pb2 pa2 Shuttle valve 2S
3S 1S
Remote control valve 54 Pressure B44 sensor
Y2
B42
Swing pressure switch
T
3
1
Pressure sensor
Attachment pressure B26 switch
B22
C2
15
Y3 Switch panel swing lock
Swing brake
S8
C5
A1
A2
A3
Hydraulic pump
Y1 6-way solenoid valve
Controller
10
52 A1
330.1.03.04.24A2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-14
2. Swing Parking Circuit (Brake Released) When the swing pressure switch is turned on by operating the lever, output to the swing brake solenoid valve from the controller is turned off and the swing parking brake is released by pilot pressure. Also, in order to prevent brake dragging caused by swing lateral force that is generated when digging attachments are moved with the swing lever being in neutral, a mechanism which senses main pressure and releases the parking brake is introduced. Signals from the pressure sensor on port pr1 or port pr2 of the control valve enter the controller. When either pressure reaches 15 MPa, the output to swing brake solenoid valve from the controller is turned off. This releases the swing parking brake. When the pressure switch for attachments is kept off for more than 5 seconds, the swing pressure switch will be turned off. Then 5 seconds after the pressure of the control valve pr1 or pr2 becomes 15 MPa or less, the solenoid valve turns on and the swing parking brake starts operating. When the pressure on G4 or G5 becomes 15 MPa or more, the swing brake is released. However, if the attachment switch was kept off for more than 5 seconds, the swing parking brake works. (When traveling)
Key switch
Swing pressure switch
Pressure received on pr1 or pr2 pressure sensor
Swing brake solenoid valve
Swing motor parking brake
OFF
OFF
0
OFF
Operates
15 MPa or less
ON
Operates
OFF
Released
Turns on 5 seconds after attachment pressure switch is turned OFF.
Operates
15 MPa or less
OFF
Released
15 MPa or more
OFF
Released
OFF ON
ON
pb2/B2. pa2/A2. 10. 15. 22. 27. 54. 52. A1. B22. B26. B42. B44. C2. S8. Y2. Y3.
15 MPa or more
LH swing RH swing Main hydraulic pump Main control valve Swing motor Arm cylinder Swing control valve 6 Solenoid valve bank Controller Swing pilot pressure switch Upper pilot pressure switch Pump pressure sensor P1 Pump pressure sensor P2 Swing brake pilot Swing brake switch Pilot pressure solenoid valve (blue band) Swing brake solenoid valve (pink band)
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-15
Swing Parking Circuit (Brake Released)
Swing motor A
22 B
T1
Pc5
27 Arm cylinder
pc4
P
B2 A2
pb2 pa2
Shuttle valve
Remote control valve
2S
54 Pressure B44 sensor
S2
S3
Y2 3
Lever lock
B42
1
Swing pressure switch
P1
PP PA P
P2
Pressure sensor
Attachment pressure B26 switch
B22
Control valve
15
P C2
Y3
Switch panel swing lock
Swing brake
A1
S8
A2
A3
Hydraulic pump 6-way solenoid valve
Controller
10
52 A1 330.1.03.04.24B2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-16
3. Swing Push Digging The swing pilot pressure is supplied to port pc4 via the shuttle valve and enables the swing priority variable restriction to be held to the right-hand side. Putting restriction on the parallel circuit secures swing force for enforced digging operation with raised swing pressure even when the arm and swing are operated at the same time.
pb2/B2. pa2/A2. 10. 15. 22. 27. 54. 52. A1. B22. B26. B42. B44. C2. S8. Y2. Y3.
LH swing RH swing Main hydraulic pump Main control valve Swing motor Arm cylinder Swing control valve 6 Solenoid valve bank Computer / Controller Swing pilot pressure switch Upper pilot pressure switch Pump pressure sensor P1 Pump pressure sensor P2 Swing brake pilot Swing brake switch Pilot pressure solenoid valve (blue band) Swing brake solenoid valve (pink band)
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-17
Swing Push Digging
Swing motor A
22 B
Arm cylinder
pc1 B5 A5
27
pb5 pa5-1 pa5-2 pc4
pb9 pa9
P
B2 pb2 A2 pa2 Remote control valve
Shuttle 2S valve
54
1S
Pressure B44 sensor S2
S3
Y2 2
Lever lock
4
3
B42 2
1
Swing pressure switch
P2
P1
Pressure sensor
Attachment pressure B26 6 switch
B22
Control valve
15
P C2
Y3 Switch panel swing lock
Swing brake
A1
S8
A2
A3
Hydraulic pump 6-way solenoid valve
Controller
10
52 A1 330.1.03.04.24C2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-18
Arm Circuits 1. Arm Out Circuit Oil discharged from hydraulic pump A1 is supplied to the arm (1) spool through the center bypass oil passage in the control valve. Oil discharged from hydraulic pump A2 is also supplied to the arm (2) spool through the parallel oil passage, and merges at the downstream of the arm (1) spool, then flows into the rod side of the arm cylinder via the load holding valve. Oil returning from the bottom returns to the tank oil passage via the arm (1) and (2) spools.
pa5/A5. pb5/B5. pa9. pb9. 10. 15. 25/26. 27. 54. 57.
Retracting the arm (dipper) (Arm 1) Extending the arm (dipper)(Arm 1) Retracting the arm (dipper) (Arm 2) Extending the arm (dipper) (Arm 2) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Arm (Dipper) control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-19
Arm Out circuit
Boom cylinder
T2
26
27
25
B5 A5 pb5
Arm cylinder
pb9
pa5-1 pa5-2
pa9
Cushion valve
P
15
P2
P1
C
Control valve
D A1
57
A2
A3
54 2
4 Remote control valve T
B
Hydraulic pump
10
330.1.03.06.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-20
2. Arm-In Load Holding When the arm is in neutral, oil on the arm cylinder rod side is sealed by the load holding valve check. This mechanism reduces internal leakage from the main spool. When the arm-in is operated, the pilot pressure enters port pa5 of the control valve and moves arm (1) spool to the arm-in side. Also, the pilot pressure separated from port pa5 enters port pc1 and moves the load holding valve spool to the right. Through this mechanism, the oil in the spring chamber of the load holding valve check is connected to the tank line passing the load holding valve spool. As a result, the pressure on the spring chamber decreases and the load holding valve check is released. The hydraulic oil in the rod of the arm cylinder is returned to the tank line, the arm cylinder extends and the arm moves in.
pa5/A5. pb5/B5. pa9. pb9. 10. 15. 25/26. 27. 54. 57.
Retracting the arm (dipper) (Arm 1) Extending the arm (dipper)(Arm 1) Retracting the arm (dipper) (Arm 2) Extending the arm (dipper) (Arm 2) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Arm (Dipper) control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-21
Arm-In Load Holding
Boom cylinder
T1 DR1' pc1 B5 A5 pb5
27 Arm cylinder DR1'
26
25
ARM
pb9
pa5-1 pa5-2
Detail
pa9
DR1 Load holding valve spool pc1 Load holding valve check
B5
Arm(2) Arm(1)
P2
P1
Remote control valve
P
54
Cushion valve
C
D A1
57
2
Control valve 15
A2
A3
4
T
A
Hydraulic pump
10
330.1.03.06.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-22
3. Arm-In Circuit For arm-in operation, pilot pressure is supplied to port pa5 and pa9 of the control valve and the arm spool moves to the arm-in side. At the same time, the arm load holding valve is released by the pilot pressure, and the discharged oil on the cylinder rod side is restricted by the forced regenerative release valve. This forces the returned oil to be regenerated into the cylinder bottom side via the check within arm (1) spool, securing the arm speeds required for floor digging work. When the load pressure rises on the cylinder bottom side, the forced regenerative release valve switches over to the large diameter restriction side. As a result, the orifice for return becomes large and returned oil on the rod side stops recycling.
pa5/A5. pb5/B5. pa9. pb9. 10. 15. 25/26. 27. 54. 57.
Retracting the arm (dipper) (Arm 1) Extending the arm (dipper)(Arm 1) Retracting the arm (dipper) (Arm 2) Extending the arm (dipper) (Arm 2) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Arm (Dipper) control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-23
Arm-In Circuit
Boom cylinder
T1
pc1 B5 A5 pb5
27 Arm cylinder
26
25
pb9
pa5-1 pa5-2
pa9
Detail B5
H/V
Load holding valve check
A5 pb5
Forced regenerative release valve
Remote control valve
P
Cushion valve
C
2
D A1
57
54
Control valve 15
P2
P1
A2
A3
4
T
A
Hydraulic pump
10
330.1.03.06.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-24
Boom Circuits 1. Boom-Up Circuit (Single) Oil discharged from hydraulic pump A1 is supplied to the boom (2) spool from the parallel oil passage via the control valve and merges at the downstream of the boom (1) spool. Oil discharged from hydraulic pump A2 merges with the discharged oil from the boom (2) via the boom (1) spool through the parallel oil passage and flows into the bottom side of the boom cylinder via the holding valve.
pb3. pa3. pb7. pa7. 10. 15. 25/26. 27. 28. 53. 57.
Lowering the boom (Boom 2) Raising the boom (Boom 2) Lowering the boom (Boom 1) Raising the boom (Boom 1) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Bucket cylinder Boom control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-25
Boom-Up Circuit (Single)
Boom cylinder
p pc5
26
25
27 Arm cylinder
A7 B7 pb7
pb3 pa3
pa7
P2
P1
Remote control valve
Cushion valve G
2
15
H A1
57
53
Control valve
A2
A3
4
E
T
Hydraulic pump
10
330.1.03.07.23A2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-26
2. Boom-Up Circuit (Combined) When floor digging operation is performed, the boom-up pilot pressure, which is supplied to port pc5, releases the restriction on flow to the arm by moving the swing priority variable restriction to the left. This makes the arm move smoothly.
pb3. pa3. pb7. pa7. pa5/A5. pb5/B5. pa9. pb9. 10. 15. 25/26. 27. 53. 57.
Lowering the boom (Boom 2) Raising the boom (Boom 2) Lowering the boom (Boom 1) Raising the boom (Boom 1) Retracting the arm (dipper) (Arm 1) Extending the arm (dipper)(Arm 1) Retracting the arm (dipper) (Arm 2) Extending the arm (dipper) (Arm 2) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Boom and bucket control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-27
Boom-Up Circuit (Combined)
T1
Boom cylinder
p pc5
pc1 B5 A5 pb5
27 Arm cylinder
26
pa5-1 pa5-2
25
pb9 pa9
A7 B7 pb7 pa7
pb3 pa3
Remote control valve
Cushion valve G
53
H
C
D A2
A1
57
2
Control valve 15
P2
P1
A3
4
E
T A
Hydraulic pump
10
330.1.03.07.23B2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-28
3. Boom-Down Load Holding When the boom is in neutral, oil on the boom cylinder bottom side is sealed by the load holding valve check. This mechanism reduces internal leakage from the main spool. For boom-down operation, the pilot pressure enters port pb7 of the control valve and moves the spool of the control valve to the boom-down side. Also, the pilot pressure enters port pc2 and moves the load holding valve spool to the left. Through this mechanism, the oil in the spring chamber of the load holding valve check passes the load holding valve spool creating a connection to the tank. Consequently, the pressure on the spring chamber decreases and the load holding valve check is released. The hydraulic oil at the bottom side of the boom cylinder is returned to the tank line, the rod of the boom cylinder shrinks, and the boom is lowered.
pb7/A7. pa7/B7. 10. 15. 25/26. 27. 53. 57.
Lowering the boom (Boom 1) Raising the boom (Boom 1) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Boom and bucket control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-29
Boom-Down Load Holding
Boom cylinder
T2
26
27
25
Arm cylinder
)
DR2'' pc2 A7 B7 pb7 pa7
Detail Load holding valve spool
DR2' DR2 pc2
Load holding valve check Boom(2) P2
Remote control valve
P
53
Cushion valve
G
Control valve
Boom(1)
15
H A2
57
2
A7
A3
4
F T
Hydraulic pump
10
330.1.03.07.23C2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-30
4. Boom-Down Circuit For boom-down operation, pilot pressure is supplied at port pb7 of the control valve, and the boom spool moves to the boom-down side. At the same time, the pilot pressure opens the boom load holding valve and partially regenerates the discharged oil from the bottom side of boom cylinder at the rod side via the check in the spool. (The lower the load pressure of the cylinder rod side, the more the regenerated volume will be.) When the boom is moved down as quickly as possible and the spool is at full stroke, negative pressure is generated by bleed-off oil passage in the center bypass. High pressure generation is coutrolled, and vibration of the body is reduced. Since the lack of oil is to be supplemented in the regenerative circuit, engine output can be effectively used.
pb7/A7. pa7/B7. 10. 15. 25/26. 27. 53. 57.
Lowering the boom (Boom 1) Raising the boom (Boom 1) Main hydraulic pump Main control valve Boom cylinders Arm (Dipper) cylinder Boom and bucket control lever Boom and arm (dipper) control shock absorber
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-31
Boom-Down Circuit
Boom cylinder
T2
26
25
27 Arm cylinder
(1)
DR2' pc2 A7 B7 pb7 pa7
Detail
Load holding valve check A7
H/V
B7 pb7 P2
Control valve
15 T2 P2
Cushion valve G Remote control valve
P
Bleed-off
H A2
57
A3
53
2
4
F T
Hydraulic pump
10
330.1.03.07.23D2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-32
Backup Circuits 1. Combined Circuit (Breaker Circuit) Through remote control operation, the pilot pressure that is supplied to port pb4 of the control valve switches the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the breaker. The pilot pressure operates the pressure switch at the same time. When the change-over switch in the cab is turned to breaker mode, the controller directs the engine controller by signal from pressure switch so that the speed can match the previously set engine speed. Return oil from the breaker passes by way of 3-direction valve, and oil exceeding the set pressure flows from the stop valve via the relief valve to return to the hydraulic oil tank.
pb4/B4. pa4/A4. 10. 15. 72. 76. 78. 83. A1. B25. S14. W4. Y9.
Breaker/Crusher circuit Crusher Circuit Main hydraulic pump Main control valve Control pedal 3-way selector Return filter Shut-off valve Controller Breaker pilot pressure switch Breaker/Crusher Switch Breaker safety valve Breaker/Crusher two flow solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-33
Combined Circuit (Breaker Circuit)
78 Filter
76 3-direction valve 1
83
2
83 Stop valve
W4
B4
Relief valve
83
pb4 pa4
72
1
Pressure B25 switch
T
P
2
S1
P1
Control valve
A2
A1
P
T
15
Y9
Shuttle valve B1
S2
B2
A
Solenoid valve
S14 Change-over switch
2 A1 Controller
A2
A3
1 Hydraulic pump
A1
Lep SC4608020-0EN
10
Issued 03-07
Copyright © 8020-34
2. Combined Circuit (High Speed Confluence Circuit) Through remote control operation, the pilot pressure that is supplied to port pa4 (or pb4) of the control valve switches the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the end attachment. Turning the change-over switch in the cab to crusher (2) energizes the solenoid valve so that the valve is switched over. Pilot pressure divided via remote control valve is fed in the port pa10 by way of solenoid valve. This changes over the spool to block the center-bypass circuit. The blocked discharge oil of hydraulic pump A2 flows by way of merging passage to be combined together with the discharged oil out of hydaulic pump A1 at upper flow course of the spare spool.
pb4/B4. pa4/A4. 10. 15. 72. 76. 78. 83. A1. B25. S14. W4. Y9.
Breaker/Crusher circuit Crusher Circuit Main hydraulic pump Main control valve Control pedal 3-way selector Return filter Shut-off valve Controller Breaker pilot pressure switch Breaker/Crusher Switch Breaker safety valve Breaker/Crusher two flow solenoid valve
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-35
Combined Circuit (High Speed Confluence Circuit)
78
T1
Filter pa10
76 3-direction valve
83
2
3
83 Stop valve
W4
B4 A4 ppb4 pa4
Relief valve
83
72
1
T
Pressure
B25 switch
2
S1 A1
P1
P2
A2 P
T
Control valve 15
Y9
Shuttle valve B1 S2
B2
A Solenoid valve
S14 Change-over switch
2 A1 Controller
A2
A3
1 Hydraulic pump
A1
10
330.1.03.09.17B2
Lep SC4608020-0EN
Issued 03-07
Copyright © 8020-36
NOTES .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... .................................................................................................................................................................................... ....................................................................................................................................................................................
Lep SC4608020-0EN
Issued 03-07
8021
Copyright ©
Section 8021 TRAVEL HYDRAULIC MOTOR ASSEMBLY AND DISASSEMBLY
CNH
Lep SM4608021-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8021-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 SPECIAL TORQUES ..................................................................................................................................................... 2 SPECIAL TOOLS ........................................................................................................................................................... 3 TRAVEL MOTOR ........................................................................................................................................................... 5 Disassembly ............................................................................................................................................................... 7 Assembly ................................................................................................................................................................... 9 BEARING MEASUREMENT ........................................................................................................................................ 12 INSPECTION ............................................................................................................................................................... 13 OVERLOAD RELIEF VALVE ....................................................................................................................................... 16 Disassembly ............................................................................................................................................................. 16 TROUBLESHOOTING ................................................................................................................................................. 17
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
SPECIFICATIONS See Section 1002.
SPECIAL TORQUES Screw (56) ........................................................................................................324±32.4 Nm (238.97 lbf-ft)±(23.90 lbf-ft) Pilot valve plug (35) ............................................................................................. 49 - 58.8 Nm (36.14 lbf-ft - 43.37 lbf-ft) Overload relief valve (57) ................................................................................... 98.1 - 118 Nm (72.35 lbf-ft - 87.03 lbf-ft) Plug (29) ......................................................................................................... 441 - 446 Nm (325.26 lbf-ft - 228.95 lbf-ft) Plug (42) ......................................................................................................................................... 14.7 Nm (10.84 lbf-ft) Plug (38) ......................................................................................................................................... 29.4 Nm (21.68 lbf-ft) Plug (60).......................................................................................................................................... 98.1 Nm (72.35 lbf-ft)
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-3
SPECIAL TOOLS A
A
B
C D
E
Mount metal (2 pieces) A 160 mm (6.30 in) B 70 mm (2.75 in) C 20 mm (0.79 in)
CRPH06D006A
CRPH06D001A
D E
100 mm (3.94 in) 37 mm (1.46 in)
Jig for inserting oil seal A 100 mm (3.94 in) B 7.7 mm (0.30 in) C
H
B E
C D
F
D E
Ø 67.5 mm (2.66 in) F
Ø 90 mm (3.54 in) more than10 mm (0.40 in) R 0. 5 (0.01 in)
A A B C
F G D
C B E D CRPH06D002A
Jig for pulling out brake piston (2 pieces) A 12 mm E 100 mm (3.94 in) (0.47 in) B Ø 24 mm F Ø 60 mm (2.36 in) (0.94 in) C Ø 40 mm G Ø 6.5 mm (0.26 in) (1.57 in) D 20 mm H Hex.socket head bolt 2-M6 x 100 (0.79 in)
Lep SM4608021-0EN
CRPH06D004A
Jig for inserting rear bearing A 120 mm (4.72 in) C B Ø 36 mm (1.42 in) D
Ø 42 mm (1.65 in) 3 mm (0.12 in)
Issued 09-07
Copyright © 8021-4
E F
C
E
F
D
B A
CRPH06D005A
Guide pin for rear cover (2 pieces) A 100 mm (3.94 in) D M 18 B 32 mm (1.26 in) E R2 C 25 mm (0.98 in) F 10°
A B C D
G H
J I K L
CRPH06D006B
Jig for inserting brake piston A Ø 280 mm G
2 - M 18 x 35
B
(11.02 in) P. C.D. 251 mm
H
2 - 20 drill hole
C
(9.88 in) Ø 215 mm
I
15 mm (0.59 in)
D
(8.46 in) Ø 195 mm
J
50 mm (1.97 in)
E
(7.68 in) 21 mm (0.83 in)
K
10 - plain washer
F
10 mm (0.39 in)
L
Ø 18 mm (0.71 in) 2 - M18 x 50
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-5
TRAVEL MOTOR Description
48
43
49 47 46
55 24 53 25 44 45 42 5
8
6 2 52
7
9
51
58
38
59 4
39
3
54
10 11
13
1 16 12 15 14 17
20 22 23 50 18
36
31
19
21 56
33 32 34 35 36
37 48
57
61 60 29 30
28 27
26 40 41 42 43 330.7.02.02.37A1
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
CASING PLUG OIL SEAL CIRCULAR SNAP RING EXPANDER PLUG INCLINED PISTON PISTON SEAL STEEL BALL SHAFT BEARING PIVOT SHOE PLATE CYLINDER BLOCK CYLINDER SPRING SPRING HOLDER BALL JOINT SHOE RETAINER PISTON ASSEMBLY SEPARATOR PLATE FRICTION PLATE BRAKE PISTON O-RING (SMALL) O-RING (LARGE) REAR COVER PLUG SPOOL ASSEMBLY SPRING HOLDER SPRING PLUG O-RING
Lep SM4608021-0EN
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
PILOT VALVE SPOOL PIN SPRING HOLDER SPRING PILOT VALVE PLUG O-RING CONNECTOR PLUG O-RING RESTRICTOR (BRAKE VALVE) RESTRICTOR SPRING (BRAKE VALVE) PLUG O-RING CHECK VALVE CHECK VALVE SPRING RESTRICTOR (0.6) O-RING RESTRICTOR (0.8) O-RING O-RING BEARING SHIM PARALLEL PIN VALVE PLATE BRAKE SPRING SCREW OVERLOAD RELIEF VALVE COUPLING RETAINING RING PLUG O-RING
Issued 09-07
Copyright © 8021-7
Disassembly General precautions 1. Hydraulic devices are made of precision components in general and structurally have small tolerances. Disassembling/assembling must be done in a clean area free of dust. Tools and cleaning oil must also be clean and must be handled with care. 2. If devices are removed from the main machine, first clean the surrounding areas of the port, then plug the ports and handle with utmost care to keep dust/ water from entering the inside.
!
3. Review the sectional drawings prior to disassembling and obtain the parts required according to the specific purpose/scope of the job. Do not reuse seals and O-rings that have been disassembled. Also, some parts must be replaced as subassembly because those parts are not supplied separately. 4. Pistons and cylinders, when they are brand new, do not need to be assemblied in a particular order. When disassembling, however, they need to be marked if they are to be used again. Before removing the pistons from the cylinders, mark them all so they can be put together in the exact order they were assemblied in originally.
WARNING: Keep hands and fingers away from small gaps or crevices among parts. Lifted loads also require extra attention since they may fall on your feet.
NOTE: the numbers in brackets refer to the drawing on page 3.
STEP 7
STEP 1
Guide pin
Remove the plug (29) and O-ring (30).
STEP 2 Remove spring (28), spring holder (27) and spool assembly (26). Put the mating mark on both spool assembly (26) and rear cover (24) so that spool assembly (26) should not be reversed on re-assembling. It is impossible to disassemble this spool assembly (26) further because spool assembly (26) is fixed by adhesive.
Hole for releasing brake (left)
49 47 55 24 52
STEP 3 Remove plug (42), O-ring (43), check restrictor spring (41) and restrictor (40).
STEP 4 Remove overload relief valves (57). When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to fall into the rear cover (24) or lose.
13 54
50 51 56
STEP 5 Remove pilot valve plug (35) and then, remove O-ring (36), pilot valve spring (34), spring holder (33), pilot valve spool (31) and pin (32).
STEP 6 Remove coupling (58).
Lep SM4608021-0EN
330.7.02.02.37D1
Place the motor with the shaft horizontal, remove Hex. socket head bolts Ml8 x 50 (56) of rear cover (24) leaving two on diagonally upper and lower position.
Issued 09-07
Copyright © 8021-8
STEP 8
STEP 15
Install two guide pins diagonally into rear cover (24). (Purpose: Prevention of falling rear cover).
STEP 9
19
Loosen slowly and simultaneously the remaining two Hex. socket head bolts Ml8 x 50 (56).
20 13
STEP 10 Remove rear cover (24) and brake springs (55) taking care cylinder block (13) is not coming out stuck with rear cover (24).
18
STEP 11 Keep the cylinder block (13) in its position and remove the valve plate (54). Mark the valve plate (54) and the rear cover (24) to differentiate the front from the back at assembly.
Paper pipe
STEP 12 Press the cylinder block (13) onto the pressing jig using the removed screw (56) to push out the inner race of the rear bearing (51).
Matching mark
16 15 17 14
STEP 13
330.7.02.02.37.9
Take a soft material like a sheet of paper and roll it into a tube to use for marking without scratching parts. Insert this into the piston (18) hole and mark the circumference of the cylinder block (13).
STEP 16 Remove the cylinder block (13), the spring bearing (15) and the cylinder spring (14).
STEP 17 Remove the separator plate (19) and the friction plate (20). Place the gear (bearing) extractor inner race of the bearing (51) to remove the bearing.
STEP 14 Hole for releasing brake
STEP 18 Remove the nine piston assemblies (18), the shoe retainers (17) and the ball joints (16), all at the same time. NOTE: The procedures above are for the motor as a single unit, but can also be applied on models with reduction gears. The disassembling for those can be conducted in the same manner. The job with theses models may be easier because there is less vibration due to larger shafts.
Secure the brake piston (21) with hand and push the piston (21) out by supplying air through the brake release oil hole.
!
WARNING: The procedure requires extra attention: the piston may pop out due to the air pressure.
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-9
Assembly
STEP 19
General precautions
3 10 1 6
12
1. Clean parts well with cleaning oil and blow dry with air. 2. Apply clean hydraulic oil to sliding parts prior to assembling.
4
WARNING: Keep hands and fingers away from small gaps or crevices among parts. Lifted loads also require extra attention since they may fall on your feet.
!
11 9
STEP 1
3
330.7.02.02.37I1
Remove the shoe plate (12).
STEP 20
1
Do not remove the inclined piston (6). In the event that this must come out, secure it by hand, push out by blowing air into the hole.
STEP 21 The shaft (9) will come out on its own.
STEP 22 Remove the retaining ring (4) and take out the oil seal (3).
STEP 23
CS02B533
Apply grease to the outer perimeter of the oil seal (3) as well as to the inner perimeter of the casing (1). Use jigs to gently and evenly tap the oil seal (3) into casing (1) without slanting.
STEP 2
When changing the bearings, inner and outer races are also to be removed with a bearing puller. Each must be replaced as an assembly.
3 10 1 6
12
4
9
330.7.02.02.37I1
Secure the oil seal (3) with the snap ring (4).
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-10
STEP 3
STEP 9
Insert the outer race of the bearing (10) into casing (1) and press fit the inner race into the shaft (9). Heating the inner race to approximately 100°C facilitates the insertion process here.
Plastic hammer
1 18 19 20
22 23 56
STEP 4 Place the shaft (9) into the casing (1). Prior to this procedure, grease must be applied to the working surface that contacts the seal (3).
51
STEP 5 Insert the inclined piston (6).
STEP 6 Insert the pivot (11) into the side where the markings match. Also, if the machine has been in use for a long time prior to servicing, insert in the direction so the sliding traces on the spherical part of the shoe plate (12) match the contact traces.
21
STEP 7 17 18 15 13
Jig for inserting rear bearing
Or
Jig for inserting brake piston 10-Plain washer
12
330.7.02.02.37P1
Gently tap and insert the inner race of the rear bearing (51) into the edge of the shaft (9), see jig for inserting rear bearing on page 3.
16 9
14
13
1 330.7.02.02.37O1
Apply a liberal amount of grease to the spherical section of the shoe plate (12), then install.
STEP 8 Place the piston assembly (18), shoe retainer (17), ball joint (16), spring (14) into the cylinder block (13) and insert the whole assembly into the shaft (9). The piston assembly (18) must be assembled into the original hole.
Lep SM4608021-0EN
STEP 10 The separator plates (19) and the friction plates (20) need to be installed alternately and completely. Start with a separator plate (19) and finish with one also.
STEP 11 Insert the O-rings (22) and (23) into the brake piston (21), then install the piston into the casing (1) using the jig for inserting the brake piston, see on page 3.
Issued 09-07
Copyright © 8021-11
STEP 12
STEP 18 49 47 55 24 52
Inserting spool assembly (26) to rear cover (24) coinciding mating mark made prior to disassembling, and then assemble spring holder (27) and spring (28).
STEP 19 Assemble M 42 plug (29) with O-ring (30), tighten to
the torque specified on page 2.
58
B
59
13 54
50 51 56 330.7.02.02.37D1
Install two guide pins (B) diagonally on casing (1).(Purpose: Guide for installing rear cover) Lay down rear cover (24) to mount valve plate (54) coinciding mating mark made prior to disassembling and also place brake springs (55) with ample grease to be attached to rear cover (24) while assembling. Also set shim (52), outer race of rear bearing (51) and O-rings (50), (47), (49) on rear cover (24).
STEP 13 Insert rear cover (24) to casing (1) along the guide pin, and install two Hex. socket head bolts M18 x 50 (56) diagonally upper and lower position and tight them to assemble rear cover (24) parallel. Then, install the rest of Hex. socket head bolts M18 x 50 (56) and remove guide pin and install two the remainder. When removing outer race of rear bearing (51), install shim (52) without fail. Confirm that O-rings (47), (49), (50) are installed to rear cover (24).
STEP 14 Assemble coupling (58).
STEP 15 Assemble spring (34), spring holder (33), pilot valve spool (31) and pin (32) to rear cover (24), and then install pilot valve plug (35) with O-ring (36), tighten to
the torque specified on page 2.
STEP 16 Assemble overload relief valves (57), tighten to the
torque specified on page 2.
STEP 17 Assemble restrictor (40) and restrictor spring (41) to rear cover (24), and then install G/18 plug (42) with Oring (43), tighten to the torque specified on page 2. Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-12
BEARING MEASUREMENT
E
S
F 9
10
1
51
52
24
330.7.02.02.37J
This work should be done only when you have changed bearings (10), (51), shaft (9), casing (1) or rear cover (24). Measure the assembling width «E» Take care not to incline shaft (9). Measure the depth «F» of rear cover (24) Measure them at crossed 4 places on the circuit, then calculate their mean value. When thickness of shim (52) to be used is placed as «S», the clearance «Y» can be calculated as follows: Y=F-(E+S) Select one or two shim (52) so as the clearance «Y» to come to 0-0.1 mm (clearance) on this unit.
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-13
INSPECTION Items to measure and methods of measurement 1. Sliding surfaces on cylinder block, valve plate and shoe plate Measure the roughness of the sliding surfaces of these parts using surface roughness gauge.
Criterion and remedy Table 2. Items and what to be inspected
Surface roughness: standard
Surface roughness: acceptable limit
Remedy
Surface roughness of cylinder block, valve plate and shoe plate
0.4 Zµ or below
3.0 Zµ or below
Repair or replace
Attention! Lapping is required to repair the surface roughness of cylinder block and valve plate. (Lapping material: # 1200) Measure the hardness of the sliding surfaces of shoe plate using hardness meter.
2. Clearance between piston and cylinder block Measure the outer diameter of piston and the inner diameter of cylinder using a micrometer at 3 locations at least in the longitudinal direction. The maximum outer diameter is represented as d, minimum diameter as d1, maximum hole diameter as D and minimum diameter as D1.
Table 3. Items and what to be inspected
Hardness: standard
Hardness: acceptable limit
Remedy
Shoe plate
HS78 or above
HS74
Replace
Table 4. Items and what to be inspected
Standard
Remedy
value
Allowable value
(in mm)
(in mm)
Outer diameter of piston d-d1
0.01 mm
0.05 mm
Inner diameter of cylinder bore D1D
0.01 mm
0.022 mm
0.037 to 0.047 mm
0.065 mm
Clearance D-d
Replace piston or cylinder block
Attention! All 9 pistons must be replaced together if replacement is necessary. 3. Looseness on piston and shoe Hold the shoe on the surface plate with jigs and pull out the piston upwards to measure looseness d of the piston and shoe.
Lep SM4608021-0EN
Table 5. Items and what to be inspected
Standard dimensions
Looseness of the crimping area of piston and shoe
0 to 0.1 mm
(value in mm)
Allowable (value in mm)
Remedy
0.5 mm
Replace piston
Issued 09-07
Copyright © 8021-14
Dial gauge
Piston Jigs Magnet
Shoe Surface plate
Measurement
Looseness of crimping area
330-7-02-02-37T1
Items to measure and methods of measurement 4. Negative braking force When the assembling is complete, measure the torque at start of rotation by placing a torque wrench at the end of the output shaft.
Criterion and remedy Table 6. Items and what to be inspected
Standard value (in mm)
Allowable value (in mm)
Remedy
Brake torque
1.171 Nm (0.863 lbf-ft)
1.055 Nm (0.778 lbf-ft)
Separator plate Friction plate Spring Replace all of the above
Standard of replacing friction and separating plate. When measuring parking brake torque, it needs to disassemble travelling unit to motor and reduction gear portion, and it's so hard. The right allowable value is a standard of replacing friction and separating plate. If it is impossible to disassemble travelling unit, refer to the right value. Standard of replacing friction and separating plate Measure the total thickness of 6 pieces of friction plate and 7 pieces of separating plate. And if the total thickness is below the following allowable value, replace all separating and friction plates and springs.
5. Shaft Use a roughness gauge and measure the extent of wear on the seal of the shaft. 6. Bearing Replace bearings.
7. Spline Replace parts when the wear of the spline exceeds the allowable limit. Lep SM4608021-0EN
Criteria:
33.04 mm (1.30 in)
Allowable Thickness:
31.5 mm (1.24 in)
Usable up to 0.05 mm of wear with steps. Attention! Replace the oil seal (3) also when replacing the shaft. Attention! The thickness of the shim (52) needs to be adjusted when replacing the shaft. The bearings (10 and 51) need to be replaced before the hour meter records 10,000 hours of operation. Attention! Replace the inner and the outer race also when replacing the bearings. Attention! The thickness of the shim (52) needs to be adjusted when replacing the bearings. The spline is reusable up to the 0.3 mm of wear with steps at the contact surface.
Issued 09-07
Copyright © 8021-15 Items to measure and methods of measurement 8. Overload relief valve section The pressure check and the adjustment of the overload relief section cannot be done unless the applicable test bench is available.
Lep SM4608021-0EN
Criterion and remedy Replace as a subassembly every 10,000 hours according to the main machine’s hour meter.
Issued 09-07
Copyright © 8021-16
OVERLOAD RELIEF VALVE Disassembly NOTE: As a rule, overload relief valve (57) should be handled as one service part. If there are any trouble on overload relief valve (57), replace as an assembly.
57-3
57-2 57-1 57-12 57-13 57-4
57-9 57-8
57-12 57-10 57-11 57-6 57-7 57-5
CS02B539
NOTE: Valve seat (57-3) is fitted in bore of socket (571) at clearance fit. When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to los NOTE: When assembling overload relief valve (57) to rear cover (24), apply grease sufficiently on engagement part not to drop valve seat (57-3), tighten to the torque specified on page 2. GREASE
CRPH06D015A
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-17
TROUBLESHOOTING 1.Hydraulic motor never starts SYMPTOM
CAUSE
REMEDY
Pressure never increases
Malfunction of built-in relief valve.
Repair or replace relief valve
Pressure increases
1.Parking brake is not released Clogging of restrictor
1.After inspection of clogging, repair or replace
2.Parking brake is not released Spool is installed in wrong direction
2.Re-install the spool in correct direction
3.Stuck friction or separating plate of 3.Replace friction and separating plate parking brake portion 4.Stuck brake piston
4.Repair outer dia. of brake piston or replace It.
5.Seizure of sliding piston
5.Check, repair or replace piston shoe, swash plate, cylinder block valve plate etc.
6.Malfunction of spool: - Stick between spool and body - Clogging of restrictor
6.Repair or replace
2.Hydraulic motor rotates weakly Set pressure of overload valve is correct, but brake is released belatedly
Malfunction of spool: - Stick between spool and body
Repair or replace
Negative brake is released, but motor is hard to start
High oil viscosity.
Raise oil temperature or change the hydraulic oil
Negative brake is released, but motor starts weakly
1.Negative brake is not completely 1.Check clogging of choke released. Clogging of choke of pressure release passage 2.Relief valve catches small particles
2.Wash relief valve, check or replace seat of it
3.Seizure of sliding portion
3.Check, repair or replace sliding portion
3.Drive shaft never rotate up to the set value
Rotation of drive shaft never reaches the set value
1.Shortage of oil coming in
1.Check oil flow or hydraulic circuit to motor.
2.Large wear or flaw made on shoe, cyl- 2.Check, repair or replace the parts inder block or valve plate
Lep SM4608021-0EN
Issued 09-07
Copyright © 8021-18 4.Brake refuses to work SYMPTOM Brake refuses to work
CAUSE Malfunction of negative brake: - Worn friction plate. - Broken spring.
REMEDY Check, repair or replace brake piston, friction plate, spring, etc.
Repair or replace or clean up Brake works on counter lever Malfunction of spool: operation - Stick between spool and body. - Stick of check valve or that by small particle. - Clogging of restrictor. 5.Oil leakage Oil leakage
1.Loose Hex. socket head bolt or plug
1.Fasten it with given torque
2.O-ring is torn off
2.Replace O-ring
3.Oil leaks inside gear casing
3.Replace oil seal
6.Would not shift from high to low
Would not shift from high to low
Stick of spool of pilot valve
Replace pilot valve assembly.
7.Abnormal noise Abnormal noise appear together Malfunction of spool: with big vibration when brake is - Air is caught inside brake valve slowly applied or oil is supplied to Stick between spool and body other circuits while motor is running
Bleed air Repair or replace
8.Hunting occurs while descending the slope Severe hunting while inching
Lep SM4608021-0EN
Malfunction of spool: 1) Stick between spool and body 1) Restrictor is not seated completely
Repair or replace
Interference with parking brake: 1) Permanent set or broken spring
Repair or replace
Issued 09-07
8022
Copyright ©
Section 8022 FAN MOTOR REMOVAL AND INSTALATION
CNH
Lep SM4608022-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8022-2
TABLE OF CONTENTS FAN MOTOR................................................................................................................................................................... 3 Description ................................................................................................................................................................. 3 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 4
Lep SM4608022-0EN
Issued 09-07
Copyright © 8022-3
FAN MOTOR Description
3 2 1 2
5
7
6
8
4 10
9
11 12
CRPH06B113G1
1 2 3 4 5 6
FAN MOTOR PILOT VALVE ASSEMBLY HOSE HOSE HUB BOLT
Lep SM4608022-0EN
7 8 9 10 11 12
WASHER VENTILATOR BOLT WASHER BOLT WASHER
Issued 09-07
Copyright © 8022-4
Removal
STEP 7
STEP 1
4
CRPH06B114A
Label and disconnect the hoses (4). JS00163A
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 3
STEP 8 Label and disconnect the electrical connections to the pilot valve assembly (2).
STEP 9 Remove the bolt (6) and the washer (7) from the fan motor (1) and remove the fan motor.
Installation NOTE: When installing the fan motor on the machine, proceed in the reverse order from that of removal.
1
Before operating the machine, carry out the following operations:
CT05L063
Disconnect the earth cable (-) (1) from the battery.
- Bleed and prime the fuel system (see Operator’s Manual). - Fill and bleed the engine cooling system (see Operator’s Manual). - Check the hydraulic, fuel and cooling systems for leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.
STEP 4 Refer to section 2001 and remove the radiateur and oilcooler assembly.
STEP 5 Remove the bolt (11) and the washer (12) fixing the ventilator (8) and the hub (5) on the fan motor (1).
STEP 6 Remove the bolt (9) and the washer (10) fixing the ventilator (8) on the hub (5), then remove the ventilator and the hub.
Lep SM4608022-0EN
Issued 09-07
Copyright ©
8023
Section 8023 FAN MOTOR DISASSEMBLY AND ASSEMBLY
CNH
Lep SM4608023-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 8023-2
TABLE OF CONTENTS SPECIFICATIONS ........................................................................................................................................................... 2 PREPARATION BEFORE REMOVAL/INSTALLATION................................................................................................... 2 FAN MOTOR.................................................................................................................................................................... 3 Description ................................................................................................................................................................... 3 REPLACEMENT PROCEDURE FOR THE OIL SEAL..................................................................................................... 4 Disassembly ................................................................................................................................................................. 4 Assembly ..................................................................................................................................................................... 5 REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE ......................................................................... 6 Disassembly ................................................................................................................................................................. 6 Assembly ..................................................................................................................................................................... 7 REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING OPERATIONS .............................. 8 Disassembly ................................................................................................................................................................. 8 Assembly ..................................................................................................................................................................... 8
Lep SM4608023-0EN
Issued 09-07
Copyright © 8023-3
FAN MOTOR Description
3
1
2 4
5
6
7
8
9
CRPH06B035G01
1 2 3 4 5
SNAP RING SPACER OIL SEAL PLUG SPRING
Lep SM4608023-0EN
6 7 8 9
SAFETY VALVE O-RING PILOT VALVE ASSEMBLY BOLT
Issued 09-07
Copyright © 8023-4
REPLACEMENT PROCEDURE FOR THE OIL SEAL Disassembly
STEP 3 2
NOTE: Precautions before starting the disassembly work. Before starting the disassembly work, wash the surfaces of the motor and the shaft so that foreign substance may not enter into inside of the motor.
STEP 1
CRPH06B020A01
Remove the spacer (2).
STEP 4
CRPH06B018A01
3
Place the motor on the work bench so that its shaft may be directed upward.
STEP 2 1
CRPH06B021A01
Using a gimlet type tool (ice pick, etc.), remove the oil seal (3).
3
CRPH06B019A01
Using snap ring pliers, remove the snap ring (1).
CRPH06B022A01
WARNING: Be careful not to receive injury to your fingers by the gimlet type tool (ice pick, etc).
Lep SM4608023-0EN
Issued 09-07
Copyright © 8023-5
STEP 5
STEP 3
CRPH06B023A01
CRPH06B024A01
Remove the foreign substance remaining in the seal groove to clean the groove completely. NOTE: When cleaning, take care that foreign matter will not enter the bearing.
Assembly STEP 1 3 A
B C CRPH06B025A01
Install the oil seal into the seal groove using a press-fitting tool. (A) 5. 2± 0. 1 (B) Ø 26 (C) Ø 44 CRPH06B022A01
After applying grease on the inside surfaces of the lip of the oil seal (3), install the oil seal into the shaft.
STEP 4
1
STEP 2 2
CRPH06B019A01
Using snap ring pliers, install the snap ring (1) into the ring groove. CRPH06B020A01
Install the spacer (2).
Lep SM4608023-0EN
NOTE: Check and make sure that the snap ring is being inserted securely into the ring groove.
Issued 09-07
Copyright © 8023-6
REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE Disassembly
STEP 2
STEP 1
5 6
4
CRPH06B028A01
CRPH06B026A01
5
NOTE: Precautions before starting the disassembly work. Before starting the disassembly work, wash the surfaces of the motor and the neighborhood of the plug so that foreign substance may not enter into inside of the valve.
6
Place the motor on the work bench so that its plug may be directed sideway.
CRPH06B029A01
Remove the spring (5) and the safety valve (6).
STEP 3
CRPH06B027A01
Remove the plug (4).
CRPH06B030A01
Remove the foreign substance remaining on the safety valve mounting surface to clean the surface completely.
Lep SM4608023-0EN
Issued 09-07
Copyright © 8023-7
Assembly
STEP 3
STEP 1 5 6
4 CRPH06B026A01
CRPH06B027A01
After applying the engine oil, install the safety valve (6) and spring (5)
Tightening torque for the plug (4): 147 to 186.2 Nm (108 ~ 137 lb-ft).
STEP 2
CRPH06B031A01
Tighten the plug (4) after setting the O-ring (7) to the plug. NOTE: When carrying out the tightening work, fix to stabilize the motor body using a press machine, etc.
Lep SM4608023-0EN
Issued 09-07
Copyright © 8023-8
REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING OPERATIONS Disassembly
Assembly
STEP 1
STEP 1 10
NOTE: Before starting the disassembly work, wash the surfaces of the motor and the neighborhood of the pilot valve so that foreign substance may not enter into the motor body side.
11
8
12
8 CRPH06B034A01
Check the O-rings (10), (11) and (12) are installed on the new pilot valve (8).
9
STEP 2
CRPH06B032A01
Place the motor on the work bench so that the pilot valve may be directed sideway. Remove 4 pcs. of the mounting bolts (9) and remove the pilot valve (8).
8
STEP 2
9 CRPH06B032A01
Setting the pilot valve (8) to the motor body, tighten 4 pcs. of the mounting bolts (9) to a torque of 27.5 to 34.3 Nm (20 ~ 25 lb-ft).
CRPH06B033A01
Clean the pilot valve mounting surface completely.
Lep SM4608023-0EN
Issued 09-07
Copyright ©
Section
FAN PUMP REMOVAL, DISASSEMBLY, ASSEMBLY AND INSTALLATION
CNH
Lep SM4608024-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
8024
8024
Copyright © 8024-2
TABLE OF CONTENTS SPECIAL TOOLS ............................................................................................................................................................. 2 FAN PUMP....................................................................................................................................................................... 3 Description ................................................................................................................................................................... 3 Removal ....................................................................................................................................................................... 4 Disassembly................................................................................................................................................................. 5 Assembly ..................................................................................................................................................................... 6 Installation ..................................................................................................................................................................... 7
SPECIAL TOOLS
CRPH06B047A01
JIG: φ39mm (Outside Dia). x φ29mm (Inside Dia) x 100mm (Length).
Lep SM4608024-0EN
Issued 09-07
Copyright © 8024-3
FAN PUMP Description
3 2 1
CRPH06B037G01
1 2 3
SNAP RING OIL SEAL PLATE
Lep SM4608024-0EN
Issued 09-07
Copyright © 8024-4
FAN PUMP Removal STEP 1
JS00163A1
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see section 8000).
STEP 3 1 3
2
CRPH06B040A01
Label and disconnect the hoses (1) and (2). Remove the screws (3) fixing the fan pump and remove the fan pump.
Lep SM4608024-0EN
Issued 09-07
Copyright © 8024-5
Disassembly
STEP 3
NOTE: Before decomposition, please wash the pump surface and the spline shaft, and make sure that a forign object should not go into the inside of a pump.
STEP 1 2
CRPH06B043A01
Remove the oil seal (2) using a gimlet (Ice Pick). NOTE: Don't make a scrath on the shaft surface by a gimlet. Be careful not injured using a gimlet (Ice Pick). CRPH06B03A01
STEP 4
Put the pump on a work bench. Which the spline shaft to be right overhead.
STEP 2 3 1
CRPH06B044A01
CRPH06B042A01
Remove the snap ring (1) using a snap ring plier.
CRPH06B045A01
Remove the plate (3) and take away the rubbish in the seal housing.
Lep SM4608024-0EN
Issued 09-07
Copyright © 8024-6
Assembly STEP 1
3
CRPH06B050A01
CRPH06B044A01
Clean up the plate (3) and install it in the bottom of seal housing.
STEP 2
CRPH06B051A01
Install the oil seal (2) using the jig (see special tool page 2).
STEP 3 CRPH06B048A01
1
2
CRPH06B042A01 CRPH06B049A01
Lep SM4608024-0EN
Install the snap ring (1) using a snap ring plier.
Issued 09-07
Copyright © 8024-7
Installation NOTE: When installing the fan pump on the machine, proceed in the reverse order from that of removal. Before operating the machine, carry out the following operations: - Bleed and prime the fuel system (see Operator’s Manual). - Fill and bleed the engine cooling system (see Operator’s Manual). - Check the hydraulic, fuel and cooling systems for leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.
Lep SM4608024-0EN
Issued 09-07
Copyright © 8024-8
NOTES ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................
Lep SM4608024-0EN
Issued 09-07
Copyright ©
Section 8030
CNH
Lep SC4608030-0EN
Copyright © 2007 CNH France S.A. Printed in France March 2007
8030
HYDRAULIC COMPONENT FUNCTIONS
Copyright © 8030-2
TABLE OF CONTENTS HYDRAULIC PUMP ................................................................................................................................................ 3 CONTROL VALVE .................................................................................................................................................. 6 SWING UNIT......................................................................................................................................................... 23 TRAVEL UNIT ....................................................................................................................................................... 28 FAN MOTOR FOR HYDRAULIC DRIVE .............................................................................................................. 40
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-3
HYDRAULIC PUMP Structure and Principle of Operation This pump couples two pumps placed on the same axis with the 1st gear (114) and distributes the rotational force to the different axes. The rotational force transmitted from the motor to the front side drive shaft (111) drives the two pumps and also drives the backup pump installed on the other axis simultaneously. This pump consists of four major sections: the rotary group that is the main part of the pump governing the rotation, the swash plate group that adjusts discharge rate, the valve block group that switches between intake and discharge of oil, and the PTO group that transmits the rotational force from the gear pump drive shaft. The rotary group is composed of the drive shaft F (111), cylinder block (012), piston shoes (151 and 152), retainer (153), spherical bush (156) and cylinder spring (157). Both ends of the drive shaft are supported by bearings (123 and 124). The shoe forms a spherical joint crimped by a piston and contains a pocket area in order to reduce the thrust force generated by the loading pressure and to balance the oil pressure so that it slides lightly on the shoe plate (211). The subgroup of the piston shoe is pressed on the shoe plate by the cylinder spring via the retainer and spherical bushing in order to facilitate its smooth movement on the shoe plate. The cylinder block is also pressed on the valve plate (313) by a cylinder spring. The swash plate group consists of the swash plate (212), shoe plate (211), swash plate support (251), tilting bush (214), tilting pin (531), and servo piston (532). The swash plate is supported on the swash plate support by the cylindrical part formed on the opposite side of the shoe sliding side. The hydraulic force, which is controlled by the regulator, is directed into the hydraulic compartment located on both sides of the servo piston. This causes the servo piston to move back and forth. The movement of the servo piston makes the swash plate swing on the swash plate support via the spherical part of the leaning pin and changes the angle of incline (α). The valve block group consists of the valve block (312), valve plate (313) and valve plate pin (885). The valve plate, which has two claw-shaped ports, is installed on the valve block. It supplies oil to and recovers oil from the cylinder block. Oil that is switched by the valve plate enters the external piping through the valve block. The PTO group consists of the 1st gear (114), 2nd gear (117) and 3rd gear (118). The 2nd and 3rd gears are supported by bearings (126 and 125) and are installed on the valve block. When the drive shaft is driven by the motor (electric motor, engine, etc.), the cylinder block rotates simultaneously via the spline connection. When the swash plate is inclined, the piston located inside the cylinder block moves back and forth with respect to the cylinder as it rotates with the cylinder block. Specifically, when the cylinder block rotates one full turn, the piston moves away from the valve plate (oil is drawn in) during the first 180 degrees and moves towards the valve plate (oil is discharged) during the remaining 180 degrees. When the angle of the swash plate is zero, the piston does not move and oil is not discharged. The rotation of the drive shaft is led to the 1st gear (114), transmitted to the 3rd gear (118) through the 2nd gear (117) and drives the backup pump connected to the 3rd gear.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-4
Hydraulic pump drawing
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-5
Description No. 04
PART NAME
QTY.
GEAR PUMP
1ST
CONSTITUENT PART(QTY) ZX15LPRZ2
05
PTO ASS'Y
1ST
011
PISTON ASS'Y
2ST
151(9PC), 152(9PC)
013
CYLINDER(R) ASS'Y
1ST
141(1PC), 313(1PC)
014
CYLINDER(L) ASS'Y
1ST
141(1PC), 314(1PC)
030
SWASH PLATE ASS'Y
2ST
212(1PC), 214(1PC)
041
CHECK VALVE 1 ASS'Y
2ST
541(1PC), 543(1PC), 545(1PC)
042
CHECK VALVE 3 ASS'Y
2ST
541(1PC), 544(1PC), 545(1PC)
079
PROPORTINAL REDUCING VALVE ASS'Y
1ST
KDRDE5KR-V3-V
NO. 111 113 114 123 124 127 012 151 152 153 156 157 211 212 214 251 261 263 271 312 313 314
PARTNAME DRIVE SHAFT(F) DRIVE SHAFT(R) GEAR 1ST ROLLER BEARING NEEDLE BEARING BEARING SPACER CYLINDER BLOCK PISTON SHOE RETAINER SPHERICAL BUSH CYLINDER SPRING SHOE PLATE SWASH PLATE TILTING BUSH SWASH PLATE SUPPORT SEAL COVER(F) SEAL COVER(R) PUMP CASING VALVE BLOCK VALVE PLATE(R) VALVE PLATE(L)
Lep SC4608030-0EN
QTY 1 1 1 2 2 3 2 18 18 2 2 18 2 2 2
NO. 401 406 466 468 490 492 531 532 534 535 541 543 544 545 548
PARTNAME HEX SOCKET HEAD BOLT HEX SOCKET HEAD BOLT PLUG PLUG PLUG PLUG TILTING PIN SERVO PISTON STOPPER(L) STOPPER(S) SEAT STOPPER 1 STOPPER 2 STEEL BALL FEED BACK PIN
QTY 8 8 2 4 27 12 2 2 2 2 4 2 2 4 2
2
702
O-RING
2
1 1 2 1 1 1
710 714 717 719 724 725
O-RING O-RING O-RING O-RING O-RING O-RING
2 1 2 2 16 6
NO. 728 732 774 789 792 808 824 885 886 901 953 954 981 983
PARTNAME O-RING O-RING OIL SEAL BACKUP RING BACKUP RING NUT STOP RING VALVE PLATE PIN SPRING PIN EYE BOLT SET SCREW SET SCREW NAME PLATE PIN
QTY 4 2 1 2 2 4 2 2 4 2 2 2 1 2
Issued 03-07
Copyright © 8030-6
Internal structure drawing of PTO
Description No. 115 117 118 125 126 128 262 326 435 468 710 728 825 826 827 886
PART NAME IDLER SHAFT GEAR 2ND GEAR 3RD BALL BEARING ROLLER BEARING BEARING SPACER COVER GEAR CASE HEX SOCKET HEAD BOLT PLUG O-RING O-RING SNAP RING SNAP RING SNAP RING PIN
Lep SC4608030-0EN
QTY. 1 1 1 2 1 2 1 1 8 1 1 1 1 1 1 2
Issued 03-07
Copyright © 8030-7
CONTROL VALVE Operation
1. Operation with all spools in neutral position 1) Neutral passage (Figures 1 and 2) Oil supplied from Port P1 enters the tank passage Ta from neutral passage L1, passing the restriction Lc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5. Oil supplied from Port P2 passes the tank passage Ta through neutral passage R1, passing the restriction Rc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5. Pressures in the pressure chambers L2 and R2 located in the upstream of the low pressure relief valve are directed to the pump through Ports ps1 and ps2 and control the delivery volumes of pumps P1 and P2. In addition, if a large amount of extra oil flows into the neutral passage, the low pressure relief mechanism functions to prevent pressures on Ports ps1 and ps2 from increasing abnormally.
2) Regulator operation explanation diagram Oil supplied from port PP goes into port PT through throttle [Lc3]. It also flows into the tank passage [Ta] through the land [Rc3], passing through the land [Lc4] and passage (5). Part of the oil supplied from port PP goes into port PA through throttle [Lc5]. It also flows into the tank passage [Ta] through the boom 1 spool land [Rc4], passing the passages [L4], (8) and [R4]. The oil that has passed through throttle [Lc6] flows into the tank passage [Ta] through the land [Lc7]. It also passes through passage (4) and flows into the tank passage [Ta] through the travel spool land [Rc5].
[fig. 1] NTROL VALVE
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-8
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-9
Single operation
1. Travel spool switching (Figures 3 and 4) When switching the travel spool by adding pressure through the pilot port Pb1 (Pa1) in travel (Section 1), the oil supplied from port P1 flows into port B1 (A1) passing through the neck part of the spool via neutral passage [L1]. The returning oil passes through the neck part of the spool via port A1 (B1) and returns to the tank passage [Ta]. When switching the travel spool by adding pressure through pilot port Pb6 (Pa6) in travel (Section 6), the oil supplied from port P2 flows into port B6 (A6) passing through the neck part of the spool or passage [S6-1] via neutral passage [R1]. At this moment, because pressures on parallel passages [R3] and [S6-1] are equal, the poppet [S6-2] does not open. The returning oil passes through the neck part of the spool via port A6 (B6) and returns to the tank passage [Ta]. When switching only one side of the spool in travel (Section 1 or 6), land [Lc4] or [Rc3] closes. Since the flow of oil supplied from port PP to the tank passage is shut off, the pressure on port PT increases.
fig.3
fig.4
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-10
2. Swing spool switching [Fig. 5] When switching the swing spool by adding pressure through pilot port Pb2 (Pa2) in swing (Section 2), the neutral passage [L1] closes. Oil supplied from port P1 passes from parallel passage [L3] through load check valve [S2-1], passage [S2-2] and the neck part of the spool and flows into port B2 (A2). The returning oil passes through the neck part of the spool via port A2 (B2) and returns to the tank passage [Ta].
fig.5
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-11
3. Boom spool switching 1) Neutral Position [Fig. 6] This valve has an anti-drift valve installed on the cylinder bottom side of boom 1. In the neutral position, the poppet [AD1] is firmly seated by the pressure on port A7 that is directed to the spring chamber [AD5] through the passage [AD2], spool [AD3] and passage [AD4].
2) Boom-up (2-pump confluence) [Fig. 7] When switching the boom 1 spool by adding pressure through pilot port Pa7 in boom 1 (Section 7), the neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load check valve [S7-1] and the neck part of the spool and flows into port A7. When switching the boom 2 spool by also adding pressure through pilot port Pa3 in boom 2 (Section 3), the neutral passage [L1] closes. Oil supplied from port P1 passes through the parallel passage [L3], the load check valve [S3-1], the neck part of the spool and passage (6), and merges and flows into port A7. The returning oil passes through the neck part of the spool via port B7 and returns to the tank passage [Ta].
3) Boom-down (regeneration) [Fig. 8] When switching the boom 1 spool by adding pressure through pilot port Pb7 in boom 1 (Section 7), the neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load check valve [S7-1] and the neck part of the spool and flows into port B7. When switching the spool [AD3] in the anti-drift valve by adding pressure to port pc2 and reducing the pressure in spring chamber [AD5] at the same time, the poppet [AD1] opens and the returning oil from port A7 returns to tank passage [Ta]. Part of the returning oil pushes open the poppet [S7-3] in boom 1 spool, passes through the passage [S72] and merges into port B7 to prevent cavitation on the cylinder rod side.
fig.6
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-12
.
fig.7
fig.8
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-13
4. Backup spool switching [Fig. 9] When switching the backup spool by adding pressure through pilot port Pb4 (Pa4) in backup (Section 4), the neutral passage [L1] closes. Oil supplied from port P1 passes through the load check valve [S4-1], the passage [S4-2] and the neck part of the spool through the parallel passage [L3] and flows into port B4 (A4). When switching the neutral cut spool [R] at the same time by adding pressure through port Pa (Fig. 1), the oil supplied from port P2 passes through passage (11) and poppet [S4-3] to merge and flow into passage [S4-2]. The returning oil passes through the neck part of the spool via port A4 (B4) and returns to the tank passage [Ta].
5. Bucket spool switching [Fig. 10] When switching the bucket spool by adding pressure through pilot port Pb8 (Pa8) in bucket (Section 8), the neutral passage [R1] closes. Oil supplied from port P2 passes through the load check valve [S8-1], the passage [S8-2] and the neck part of the spool through the parallel passage [R3] and flows into port B8 (A8). The returning oil passes through the neck part of the spool via port A8 (B8) and returns to the tank passage [Ta].
fig.9
fig.10
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-14
6. Arm spool switching 1) Dump (2-pump confluence) [Fig. 11] When switching the arm 1 spool by adding pressure through pilot port Pb5 in arm 1 (Section 5), the oil supplied from port P1 flows into port B5 passing through the load check valve [S5-1], the passage [S5-2] and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also adding pressure through pilot port Pb9 in arm 2 (Section 9), the oil supplied from port P2 passes through the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (10) via the neutral passage [R1] to merge and flow into port B5. The returning oil passes through the neck part of the spool via port A5 and returns to the tank passage [Ta].
fig.11
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-15
2) Crowd (2-pump confluence) [Fig. 12] When switching the arm 1 spool by adding pressure through pilot port Pa5 in arm 1 (Section 5), the oil supplied from port P1 flows into port A5 passing through the load check valve [S5-1], the passage [S5-2] and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also adding pressure through pilot port Pa9 in arm 2 (Section 9), the oil supplied from port P2 passes through the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (9) via the neutral passage [R1] to merge and flow into port A5. When switching the spool [AD3] in the anti-drift valve by adding pressure to port pc1 and reducing the pressure in the spring chamber [AD5] at the same time, the poppet [AD1] opens and the returning oil from port B5 passes through the neck part of the spool, the passage [S5-3] and the arm variable regenerative throttle [Lc8] to return to tank passage [Ta]. Part of the returning oil pushes open the poppet [S5-4] in arm 1 spool, passes through the passage [S5-2] and merges into port A5 to accelerate the cylinder speeds. It also prevents the cavitation on the bottom side.
3) Variable regeneration (during crowding) [Fig. 13] During arm crowding, the spool [S5-6] strokes according to the pressure at the passage [S5-2], which was directed through the passage [S5-5], so the opening of arm variable regenerative throttle [Lc8] changes accordingly. If the pressure at the passage [S5-2] is high, the stroke of spool [S5-6] increases and the opening of throttle [Lc8] becomes larger. On the other hand, if the pressure at the passage [S5-2] is low, the stroke of spool [S5-6] decreases and the opening of throttle [Lc8] becomes smaller. Thus, the regenerating flow varies according to the bottom pressure on the arm cylinder.
fig.12
Arm variable regenerative throttle
fig.13
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-16
7. Neutral cut spool switching [Fig. 14] This valve has a neutral cut spool installed at the lowest stream of the neutral passage [R1] (at the upper stream of the low-pressure relief valve). When switching the neutral cut spool [R] by adding pressure to port Pa10, the neutral passage [R1] closes. Oil supplied from port P2 passes through passage (11), poppet [S4-3] (Fig. 10) and merges and flows into passage [S4-2] in backup (Section 4).
8. Parallel throttle for arm [Fig. 14] This valve’s parallel circuit for the arm has throttle valves installed in both arm 1 (Section 5) and arm 2 (Section 9). Consequently, the arm speeds are kept from slowing down even in combined operations. The parallel circuit in arm 2 (Section 9) is connected with the passage [S9-2] (Fig. 12) after being restricted by throttle [Rc6] at the end of poppet [S9-3] through parallel passage [R3]. The parallel circuit in arm 1 (Section 5) pushes open the poppet [S5-8] through parallel passage [L3] and is connected with passage [S5-2] (Fig. 12) after being restricted by throttle [Lc9] in the parallel variable throttle spool. The degree of restriction for throttle [Lc9] can be changed by adding pressure onto pilot ports Pc4 and Pc5.
Arm parallel variable throttle
Arm parallel throttle Neutral cut spool
fig.14
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-17
9. Relief valve 1) Main relief valve (Fig. 15) Oil supplied from port P1 passes through the poppet [LP], and oil supplied from port P2 passes through the poppet [RP] and passage (3). The two flows of oil are thus directed to the main relief valve. The operation of the main relief valve regulates the maximum pressure on the P1 and P2 sides of the pump.
2) Overload relief valve In each cylinder port of boom 1, arm 1 and bucket, an overload relief valve is installed to prevent an abnormal boost of pressure on the actuator due to external force. This relief valve also prevents cavitations by drawing oil in from the tank when pressure on the cylinder port becomes negative.
fig.15
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-18
Combined Operations
1. Added operation with travel (Fig. 16) If a task other than travel takes place during travel right/travel left movement (during forward/reverse or pivot turning), or if travel right/travel left movement takes place while a task other than travel is being performed, the oil supplied from port PP is shut off from the tank passage [Ta] at the signal land section (other than travel) which has switched over to lands [Lc4], [Lc7], [Rc3] and [Rc5]. As the result, the pressure in the signal passage will rise up to the set relief pressure, which is the source of oil pressure for signals. A rise in signal pressure switches the straight travel spool. The pressures on port PT and PA also increase. Once the straight travel spool is switched over, oil supplied from port P1 flows from the neutral passage [L1] into travel (Section 1). It also passes through passage (2), the neck part of the straight travel spool and neutral passage [R1] and flows into travel (Section 6). Oil supplied from port P2 passes through the neck part of the straight travel spool and passage (1) and flows into the parallel passage [L3]. If the negative pressure on sections other than travel is higher than the negative pressure on travel (Section 6), part of oil supplied from port P2 pushes open the poppet [S6-2] and passes through the throttle at the end of the poppet and merges in passage [S6-1]. Since travels (Sections 1 and 6) are achieved with oil supplied from port P1 and tasks other than travel are achieved with oil supplied from port 2, the straight travel is maintained during combined operation during travel right/left movement or combined operation with other machines.
fig.16
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-19
Anti-drift Valve This anti-drift valve is attached on the cylinder port of the arm rod (bottom side of boom) to prevent a natural drop of the arm (boom) cylinder. In neutral (Fig. 17), pressure on the cylinder port passes through the neck of spool [AD3] via passage [AD2] and is directed to the spring chamber [AD5] through passage [AD4]. The force of the spring and the pressure differential in the poppet areas firmly seats poppet [AD1]. During arm dump (boom-up) (Fig. 18), oil supplied from the pump pushes open the poppet [AD1] and flows into the cylinder port. During arm crowding (boom-down) (Fig. 19), pressure is applied to pc1 (pc2) to switch over spool [AD3], directing oil from the spring chamber [AD5] into the drain port DR1 (DR2) via passage [AD6] to open the poppet [AD1]. As a result, oil returning from the cylinder port flows into the tank passage [Ta].
fig.17 AD3 (With spool switched over)
fig.18 fig.19
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-20
Relief Valve
1. Operation of the main relief valve [1] This relief valve is integrated between the neutral passage “HP” and low pressure passage “LP”, and oil passes the orifice in the poppet (C) and fills the internal space (D). The sleeve (E) and main poppet (C) act on different areas (A and B). They are firmly seated.
[2] If the pressure in the neutral passage “HP” reaches the set spring force of the pilot poppet, the pilot poppet (F) opens. The oil flows around the poppet and drilled hole (G) and is directed into the low pressure passage “LP”.
[3] Since the pilot poppet has been opened, the pressure in (D) reduces and the main poppet (C) opens. As a result, the oil flows directly into the passage “LP”.
Boost operation When applying pressure to the pilot port PH, the piston (H) moves to the set position by plug (I). Due to this, the pilot spring force rises and the pressure in “HP” rises.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-21
2. Operation of the overload relief valve [1] This relief valve is integrated between the cylinder port “HP” and low pressure passage “LP”, and oil passes the orifice in the piston (C) and fills the internal space (G). The sleeve (K) and main poppet (D) act on the different areas (A) and (B). They are firmly seated.
[2] When the pressure in the cylinder port “HP” reaches the set spring force of the pilot poppet, the pilot poppet (E) opens. The oil flows around the poppet and drilled hole (H) and is directed into the low pressure passage “LP”.
[3] Since the pilot poppet (E) has been opened, a flow passing orifice (I) in the piston (C) is generated. This flow produces a differential pressure between the passage “HP” and the backside of the piston (C). This moves the piston (C) until it seats on the poppet (E).
[4] The oil flow from the passage “HP” to the backside of the poppet (D) is only through the poppet (D), annular space in the piston (C) and the orifice (F). As a result, the differential pressure increases. Due to this, the poppet (D) opens, and the oil flows directly into the passage “LP”.
F
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-22
3. Draw-in-oil feature of the overload relief valve
A
B
K
[1] This relief valve has an anti-void unit incorporated. This unit supplies oil to the cylinder port “HP” when cavitation takes place. When the pressure in the cylinder port “HP” is lower than the low pressure side “LP”, the differential pressure between (A) and (B) opens the sleeve (K). As a result, oil enters the cylinder port “HP” through the low pressure side “LP” and this prevents cavitation.
4. Function of low-pressure relief valve [1] When oil doesn't flow
[2] Neutral spool Oil from a neutral passage “HP” flows to a flow low-pressure passage “LP” in signal orifice “A”. The pressure of the signal port “4Ps(5Ps)” goes up by signal orifice “A”.
[3] Function of low pressure relief The poppet “B” opens, and when it becomes pressure set with spring “C” when excessive oil flows to a neutral passage “HP”, it flows directly to “LP” and oil from a neutral passage “HP” prevents the abnormality pressure being generated.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-23
SWING UNIT Configuration of Components Swash plate type axial piston motor
Mechanical brake Makeup valve
Relief valve Bypass valve NOTE: Numbers in parentheses in the following text correspond to the circled numbers in the Internal structural drawings.
Structure of Hydraulic Motor The rotary component group is composed of a drive shaft integrated type cylinder [27] and nine piston assembly [8] arranged in the cylinder [27]. Additionally, both ends of the cylinder [27] are supported with bearings [4] and [25]. Piston assembly [8] are guided by return plates [6] and spring bearings [7] so that they can slide on the cam plates [5] smoothly. The balance plate [24] is pressed against the end face of cylinder [27] by the force of coned disc spring [17] and hydraulic pressure acting on the bushing [15]. Mechanical brakes [9], [10], [11] and [14] that are used as parking brakes are installed between the circumference of cylinder [27] and the housing [28]. Also, a relief valve [31] as cushion and makeup valves [35], [36] and [39] for preventing cavitation are built in the cover section [29]. In order to prevent swinging-back when swing operation is stopped, a bypass valve [43] is integrated into the cover [29].
Operational Description of Hydraulic Motor Hydraulic oil supplied from the pump via the control and other valves enters from port A (or port B) on the cover [29] and is discharged from port B (or port A). Oil leaked from gaps in each sliding part is returned to the tank through the drain port "a" on the cover [29]. The pressurized oil supplied to port A is supplied to the piston hole "f" in the cylinder [27], passing the following components in order: passage "b" in the cover [29], passage "c" on the bushing [15] section on the cover [29], passage "d" on the balance plate [24] which has a crescent-shaped port switching between supply and discharge every 180° per one motor turn, as well as, passage "e" on the cylinder [27]. The oil pressure acts on piston assembly [8], resulting in piston assembly [8] being pressed to the cam plate [5] via the shoe section. Because the sliding face of the shoe on cam plate [5] is inclined at a given angle, the pressing force on the piston assembly [8] to which the oil pressure pushes, is transformed into a force that slides the shoe on the swash plate. Because the spherical shoe section of piston assembly [8] is connected so that it works as a universal joint, the shoe's sliding force on the swash plate is transferred to the motor output shaft as a turning force via the piston assembly [8] and cylinder assembly [27]. As mentioned above, each piston assembly [8] receives the pressurized oil while it travels the stroke from the top dead center to the bottom dead center of the incline plane and transforms it into a turning force to revolve cylinder assembly [27] and discharges oil while it travels the stroke from the bottom dead center to the top dead center. The discharge route is the reverse of the supply route described above and the oil is discharged from port B. The hydraulic motor operates in the manner as described above. Its output torque and the number of revolutions are determined according to the hydraulic force and the volume of oil supplied respectively.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-24
Operational Description of Mechanical Brake Friction plate [9] is connected to the circumference of cylinder assembly [27] via spline. Also, the counterpart plate [10] is connected to the housing [28]. When the pressure in the mechanical brake release chamber is zero, the cylinder assembly [27] (output shaft) is locked and will not turn as a result of the brake piston [11] pressing the counterpart plate [10] and friction plate [9] through the spring force [14]. In the opposite manner, when the oil pressure of 2.9 to 4.9 MPa is reached on the brake release chamber, the brake piston [11] overcomes the force and moves until it hits the end face of the cover [29], creating space between friction plate [9] and counterpart plate [10]. As a result, the mechanical brake turns to a released status.
Operational Description of Make-up Valve
1. Half-braking condition (a state where relief valve [31] is not in operation) When decelerating the swing body through the control valve using the half-lever function after accelerating the swing body, the supply volume to port A from the pump decreases but it is necessary to supplement oil when the swing body is rotating at a relatively high speed because the pressure applied to the "c" section tends to become negative due to motor's pumping action. However, because the whole volume of oil which flows into "c" section from port A is discharged into control valve via port B when the pressure on port B is lower than the working pressure of relief valve [31], the absolutely necessary oil volume at the "c" section is not met with the oil volume from the control valve alone (as the valve is in the half-lever position, the oil volume is still restricted). To prevent this, makeup check [39] is provided to supplement "c" section to make up for a lack of oil through the makeup port.
2. Full braking condition (a state where relief valve [31] is in operation) When changing to the neutral position from condition A by quick lever operation, the swing body is turned by inertial force even though the oil supply volume from the pump to port A becomes zero. In this case, relief valve [31] on the port B side operates, and the oil, which blew off the relief, passes oil passages "g" and "h", presses open the makeup check [39] on port A and is supplemented to the passages "b" and "c". However, the oil lacks by its volume that which has leaked into the case drain of the motor. To prevent this, the makeup check [39] is opened from the makeup port and the oil flows into the passages "b" and "c" in order to prevent cavitation.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-25
Operational Description of Relief Valve (Internal structural drawing of relief valve)
1. When starting The hydraulic oil supplied from port A by operating the control valve does not immediately reach the constant revolution level due to the large inertial force of the swing body. Part of the oil passes oil passages "g" and "h" via relief valve [31] that works as a safety valve, presses open the check [39] on port B side and flows into port B. Oil in port A presses open the poppet [47] by counteracting the force of spring [48], passes passage "g" via a space between seat [46] and poppet [47] and flows into passage "h".
2. When braking (at time of cushioning) When the control valve is returned to the neutral position, the return passage for the motor's drain oil closes. Immediately after this operation, the motor is turned by large inertial force and attempts to suck oil through port A by pumping action and to discharge it to port B. As a result, the pressure on port B increases because the return passage in the control valve is closed. As the increased pressure on port B presses open poppet [47] by counteracting the force of spring [48], the oil flows into passage "c" by pressing open the makeup check [39] via oil passages "g" and "h" through port B. In this process, the inertial force of the swing body is absorbed and the swing body comes to a stop. Also, in the pressure increasing process above mentioned, the highly pressurized oil that flowed into the front chamber of poppet [47] enters the piston chamber passing the small hole passage on the central section of piston [52] via circumferential orifice "j" of poppet [47] and moves piston [52] until it hits the end face of sleeve [51]. Meanwhile, since poppet [47] is already forcedly opened, the cushion relief begins to work at relatively low pressure, and then increases to a specified pressure in minimal time. This dual-step action decreases the impact of motor starts and stops.
Operational Description of Bypass Valve (Internal structural drawing of bypass valve) When attempting to stop the swing body after operating the control valve to drive the swing body, braking pressure is generated on one side of the port as the hydraulic motor, which keeps rotating due to its inertial force, continues its pumping action. Suppose that this is port A: This pressurized oil for braking flows into the back chamber of check [60] on the side A via small holes [a3] and [a2]. As a result, the check [60] on side A moves until it contacts and presses seat [58] on side A to shut off the bypass passage by pushing check [60] on side B, which is arranged as a counterpart, to the left in the process of decelerating the swing body. In due course, the swing body stops once but reverses due to braking pressure. Therefore, the pressure on side B increases and check [60] on side B attempts to move to the right by pushing check [60] on side A, which is arranged as a counterpart. However, this movement of check [60] is a little delayed because the oil flow of the back chamber in check [60] on side A is gently controlled through the action of the flow control valve comprised of poppet [61] on side A and spring [62] on side A. In the meantime, the pressurized oil of port B flows into the intermediate chamber via small hole "b1" and bypasses port A side via small hole "a1". Subsequently, check [60] on side B contacts and presses seat [58] on side B and moves to the position where it can shut off the bypass passage. As described above, the reverse motion will be prevented without any trapping of the oil because the pressure is bypassed to port A side in the process of generating reverse pressure on the port B side.
Lep SC4608030-0EN
Issued 03-07
Lep SC4608030-0EN
1
2
3
4
5
6
28
7
27
8
f
25
d
10
24
11
c
23
b
12
Mechanical brake release chamber
26
e
9
22
13
21
20
19
18
17
16
15
14
a
41
40
Port B
42
39
38
37 Top dead center
35
43
Port A
h
g
33 34
32
36
b
i
Bottom dead center
Relief on port A side
Relief on port B side
44 34
45
Makeup port
Drain port
29
30
31
Copyright ©
8030-26
Internal Structural Drawing
Issued 03-07
Copyright © 8030-27
Internal Structural Drawing of Externally Adjusted Shockless Relief Valve 46
47
48
49
50
51
52
53
57
56
55
54
j
Internal Structural Drawing of Bypass Valve 58
59
Port B
b3
Lep SC4608030-0EN
60
61
62
Port A
b2
b1
a1
a2
a3
Issued 03-07
Copyright © 8030-28
TRAVEL UNIT Structure
Fig.1. Structure drawing of travel motor SYM
PART NAME
1
CASING
2
NPT1/16 PLUG
3
OIL SEAL
4
RETAINING RING IRTW68
5
SHIFTER PISTON
6
PISTON SEAL
7
STEEL BALL
8
SHAFT
9
BEARING HR33209J
10
PIVOT
11
SWASH PLATE
12
CYLINDER BLOCK
13
CYLINDER SPRING
14
SPRING HOLDER
15
BALL JOINT
16
SHOE RETAINER
17
PISTON ASSY
18
SEPARATING PLATE
19
FRICTION PLATE
20
BRAKE PISTON
SYM
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
PART NAME D-RING (SMALL DIA.) D-RING (BIG DIA.) REAR COVER NPT1/16 PLUG (MEC) SPOOL ASSY SPRING HOLDER SPRING M42 PLUG O-RING 1B G40 PILOT VALVE SPOOL PIN SPRING HOLDER SPRING G3/8 PILOT VALVE PLUG O-RING 1B P14 CONNECTOR G1/4 PLUG O-RING 1B P11 RESTRICTOR (BRAKE VALVE) RESTRICTOR SPRING (BRAKE VALVE)
SYM
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
PART NAME G1/8 PLUG O-RING 1B P8 CHECK VALVE CHECK VALVE SPRING M6 RESTRICTOR (ɔ0.6) O-RING 1B P12.5 M6 RESTRICTOR (ɔ0.8) O-RING 1B P15 O-RING 215.57 X 2.62 BEARING HR32207C SHIM PARALLEL PIN VALVE PLATE BRAKE SPRING HEX. SOCKET HEAD BOLT M18 X 50 OVERLOAD RELIEF VALVE COUPLING RETAINING RING C-TYPE 40 G1/2 PLUG O-RING 1B P18
Table 1. Parts list of travel motor
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-29
Brief Explanation of Structure The motor mainly consists of the following parts: • Rotary group producing turning force to drive shaft
• • • •
Parking brake preventing host machine from self-running during its rest Capacity control parts that changes the motor capacity consequently rotating speed Overload relief valve that is attached to the rear cover Brake valve (counter balance valve) portion that control the hydraulic circuit
1) Rotary Group The cylinder block [12] is inserted into the spline of shaft [8], both ends of which are supported by bearings [9], [50]. This cylinder block [12] is pushed toward the rear cover [23] together with valve plate [53] by cylinder spring [13]. Nine pieces of piston ass’y [17] slide inside the cylinder block [12] along the surface of swash plate [11]. Hydrostatic bearings are provided on the end surface of piston ass’y [17] to reduce the sliding resistance, and the ends of piston ass'y [17] are pushed toward swash plate [11] by cylinder spring [13] through spring holder [14], ball joint [15] and shoe retainer [16].
2) Parking brake Seven pieces of separating plates [18] and six pieces of friction plates [19] are alternately set on the spline of cylinder block [12] and pushed together by 14 brake springs [54] through brake piston [20].
3) Capacity control portion They consist of: pivots [10] that support swash plate [11] and slide in two half-spherical recesses in swash plate [11] : shifter piston [5] that change the angle of swash plate [11] on the pivots [10] : stopper [1-1] of casing that limits the angle of swash plate [11] : pilot valve portion that leads the oil to shifter piston [5] by external pilot signal : three check valves [43] that select the maximum pressure from the external pilot pressure, inlet pressure and outlet pressure of the motor and send it to pilot valve portion.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-30
4) Overload relief valve This valve is screwed in the motor rear cover [23] and consists of : socket [56-1] that is screwed and fixed in the rear cover [23] and supports the valve seat [56-3] which metallically seated in the hole of rear cover [23] : valve [56-2] that contact with valve seat [56-3] by adjusting spring [56-9] and fitted in the hole of socket [56-1] : coupling piston [56-4] that fitted in the hole of the valve [56-2] and functions also as an oil passage : piston [56-7] that is inserted in the pilot body [56-6] and : shim [56-8] that adjust the spring force.
Fig.2. Structure drawing of overload relief valve
SYM
PART NAME
SYM
PART NAME
56-1
SOCKET
56-8
SHIM
56-2
VALVE
56-9
ADJUSTING SPRING
56-3
VALVE SEAT
56-10
O-RING 1B P7
56-4
COUPLING PISTON
56-11
BACK-UP RING T2 P7
56-5
CAP
56-12
O-RING 1B G25
56-6
PILOT BODY
56-13
BACK-UP RING T2 G25
56-7
PISTON
• Table 2. Parts list of overload relief valve
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-31
5) Brake valve portion Spool control pressure : 0.59 to 0.95 MPa Check valve cracking pressure : 0.015 MPa
Fig.3. Brake valve portion The brake valve portion mainly consists of the following parts: 1] Spool By shifting the spool [25], the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations. 2] Check valve (Built in the spool) This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to lock oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for hydraulic motor.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-32
Function Direction of rotation (Viewing
Inlet port
Outlet port
VB
VA
Right (Clockwise)
VA
VB
Left (Counterclockwise)
from rear cover)
Table 3. Direction of rotation
Fig.4. Lacation parts
1. Operation of motor High pressure oil delivered from hydraulic pump is led to inlet port(VA,VB) that is provided in the brake valve portion and, through the rear cover [23] and valve plate [53], led to cylinder block [12]. The oil flow and direction of shaft rotation are indicated in Table 3.
Fig.5. (a)
Fig.5. (b)
As shown in Fig.5(a), high pressure oil is supplied to the pistons which are on one side of the line Y-Y that connects upper and lower dead points and produces force F1
F1 = P x A (P : pressure, A : area of piston section) The swash plate [11] with inclined angle of α divides this force F1 into thrust force F2 and radial force F31F34 (or F35). (Fig.5 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque of T
T=r1 • F31 + r2 • F32 + r3 • F33 + r4 • F34 (In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.) This drive torque is transmitted via cylinder block [12] to driving shaft [8].
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-33
2. Operation of parking brake Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly to the rear cover [23], is applied to the brake piston [20]. Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separating plates [18], inserted into the casing [1], and friction plates [19], coupled to cylinder block [12] by the outer splines. When no pressure is activated on the brake piston [20], it is pushed by the brake springs [54] and it pushes friction plates [19] and separating plates [18] towards casing [1] and generates the friction force which brakes the rotation of cylinder block [12] and hence the shaft [8].
Fig.6. Parking brake portion
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-34
3. Operation of capacity variable mechanism
Fig.7. Operation of capacity variable mechanism Fig.7 typically shows the capacity variable mechanism. When high speed pilot line is charged with the pressure PA that overcome the spring [33], the spring [33] is compressed and spool [30] shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve [43] from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston [5]. As a result, swash plate [11] turns around the line L which connect the two pivots [10] as shown by dotted lines. The turn stops at the stopper [1-1] of casing and swash plate [11] keeps the position. In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates faster, around 1.71 times, by the same volume of oil. When no pressure is in the high speed pilot line PA , spool [30] is pushed back by the spring [33] and pressure that pressed the shifter piston [5] is released to the hydraulic tank through restrictor [45]. Here, nine pistons are there and they equally spaced on the swash plate [11]. The force that summed up those of pistons comes to almost the center of the swash plate [11] as shown. Since the pivots [10] are off-set by S from the center, the rotating force of product S and the force moves swash plate [11] to the former position and the speed returns to low. When the power demand exceeds the engine power, such as in steep slope climbing or turning at high speed mode, the system step down to the low speed automatically. The mechanism is that: pump pressure (VA or VB) is led to the port PB [Fig.7]. and this pressure activate on pin [31]. When the pressure at PB exceeds predetermined value, spool [30] returns to the left by the counter-pressure against pin [31] and the pressure on the shifter piston [5] through port C is released to the tank and the motor comes to low speed. When PB goes down, the spool [30] moves to the right and the speed become high.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-35
4. Operation of overload relief valve Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions: 1] When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating, bypasses surplus oil to return line. 2] When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the predetermined value to stop the inertial force. 3] To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these purposes, the developed pressure is kept comparatively low for a short period, then keep the line pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and sprocket etc. can be smoothly done and the shock are absorbed. When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective diameter of valve [56-2] which seats on the valve seat [56-3] and, at the same time, is delivered, via small hole, to the connecting piston [56-4] located inside the valve [56-2] and the piston bore pressure increases up to "A" port pressure. The valve [56-2] opposes to adjusting spring [56-9] by the force of the pressure exerted on the area difference between valve seat's effective diameter and piston bore and keep the predetermined pressure. When hydraulically braking, the piston [56-7] is at the left position by the driving pressure, and when "A" port pressure increases, the pressure is applied also to the piston [56-7] through the small hole in the valve [56-2] and connecting piston [56-4] moves rightward until it touches the cap [56-5]. In this while, the valve [56-2] maintains "A" port pressure at comparatively low against the adjusting spring [56-9] force and exhaust oil to "B" port side. After the piston reached to the plug, the valve acts the same as at starting.
Fig.8. Operation of overload relief valve
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-36
5. Operation of brake valve 1) Holding status (see Fig.9) When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring [27] located on both spool ends holds the spool [25] at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor. Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to the tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically prevented. If external torque is exerted on the motor shaft, the motor would not rotate as usual by this negative parking brake. In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates a bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check valve, built in the spool [25], operates to avoid the cavitation and opens the passage from VA to MA or from VB to MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.
Spring
Spring
Fig.9. Holding status
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-37
2) Accelerating operation (see Fig.10) When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool [25], and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At the same time, the pressure of pilot chamber increases to push and move the spool [25] leftwards, overcoming the spring [27] force. Thus, the return line from MB to VB opens to rotate the motor. In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief valve and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational speed goes up. the relieved volume decreases, and finally the motor rotates at a fixed speed.
Check valve with restrictor Pilot chamber
Check valve with restrictor Pilot chamber
Spring Spring
Fig.10. Accelerating operation
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-38
3) Stopping operation (see Fig.11) Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool [25] returns to the neutral position by spring [27] force. Thus, the passage from MA to VA is closed. Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last the motor stops. Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and the motor is mechanically stopped.
Pilot chamber
Pilot chamber
Spring Spring
Fig.11. Stopping operation
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-39
4) Counterbalance operation (see Fig.12) Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring [27] force moves the spool [25] leftwards towards neutral position. Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to increased resistance in the passage and the motor receives hydraulic braking effect. If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on VB port increases, and spool [25] moves rightwards to enlarge the area of passage from MA to VA. Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to correspond to the volume of supplied oil. In order to give stable counterbalance operation, the restrictors [39] are set in the pilot chamber to damp the spool [25] movement. The parking brake is released during pressure adjusting action of the spool [25].
Check valve with restrictor
Pilot chamber
Check valve with restrictor Pilot chamber
Spring Spring
Fig.12. Counterbalance operation
Lep SC4608030-0EN
Issued 03-07
Copyright ©
8030-40
FAN MOTOR FOR HYDRAULIC DRIVE Outside Drawing
Lep SC4608030-0EN
Issued 03-07
Copyright ©
8030-41
Internal Structure Drawing
No.
Lep SC4608030-0EN
Part Name
1
Output shaft
2
Case
3
Thrust plate
4
Piston assembly
5
Cylinder block
6
Valve plate
7
Retainer guide
8
Retainer shoe
9
Main bearing
10
Sub bearing
11
Oil seal
12
End cover
13
Center spring
14
Spring for suction safety valve
15
Suction safety valve
16
Variable flow control pilot valve
17
Flow control spool
18
Flow control spool spring
19
Main spool
20
Proportional solenoid
21
Filter
22
Forward/reverse changeover pilot valve
23
ON-OFF solenoid
Issued 03-07
Copyright © 8030-42
Operation Principle 1. Hydraulic Motor Function • The hydraulic motor is called as swash plate axial piston motor and it converts force of pressure oil transferred from the hydraulic pump into rotation. Operation Principle • Oil flown out of the hydraulic pump is introduced into the cylinder block [5] through the valve plate [7]. It has been so designed that the oil is to be introduced in the one side area of the line Y-Y connecting the top dead center to the bottom dead center in the piston [4] stroke. • Pressure oil entered in the one side part in the cylinder block [5] pushes each piston [4] (2 pistons or 3 pistons) to generate force F1. (F1 N=P MPa x π/4 D2 cm2) • Although the force works to the thrust plate [2], the force is divided to F2 and F3 as the thrust plate [2] is fixed with a certain angle of α° against the output shaft [1]. • Of the component of a force, the radial force F3 generates each torque of (T=F3 x ri) against the line Y-Y connecting the top dead center to the bottom dead center. • The resultant force of the torque [T= Σ(F3 x ri)] allows the cylinder block [5] to be rotated via piston as a turning force. • Since the cylinder block [5] makes a spline connection with the output shaft, the output shaft rotates to transfer the torque.
Lep SC4608030-0EN
Issued 03-07
Copyright ©
8030-43
2. Suction Safety Valve (Safety Valve with Suction) 1) Function of Suction • Negative pressure in the inlet port of motor generates cavitation. When pressure in the inlet port of the motor becomes negative, the suction valve has a function preventing cavitation from generating by supplying pressure oil from the outlet port. 2) Function of Safety Valve
Operation [1] When starting • When pressure oil flown out of the pump is supplied to the port P and pressure on MA side increases to generate staring torque in the motor, the motor starts rotation. Oil on MB side of the outlet port of motor will returns from port T to the tank.
[2] When stopping • When input speed of the fan pump gets to 0 min-1 due to engine stop, pressure oil from the pump fails to be supplied to port P. Since pressure oil will not be flown in MA side of the motor, the motor speed is being slowed down gradually to make it a stop. • When motor shaft is rotated by inertia with pressure oil flowing to port P being decreased, pressure in the inlet port becomes negative. In such case, the suction safety valve prevents cavitation from being generated by supplying pressure oil in port T on the outlet side to Ma side.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-44
Function • Discharge pressure of the fan pump may be raised in such case where the engine is started. • In order to protect fan system circuit, safety valve is installed. • When discharge pressure goes beyond the pressure set at the safety valve, the seat of safety valve opens to allow the oil to be escaped into the passage to port T to prevent unusual high pressure from being generated.
Lep SC4608030-0EN
Issued 03-07
Copyright ©
8030-45
3. Variable Flow Control Valve Function It supplies oil discharged out of the pump to the motor as necessary and allows surplus oil to return to the tank. • The motor speed is increasing in proportion to inflow quantity Q as illustrated in Fig. 1. min-1 at inflow of Q1. The pump rotates at In order to aim at noise reduction and loss reduction as a function of fan motor, it is necessary to control fan speed for maintaining necessary constant speed regardless of inflow. A flow control valve is built-in as the function meeting the requirements mentioned above. Even when inflow increases from Q0 to Q1, motor speed keeps constant as to min-1 as illustrated in Fig.1
Operation • Basic operation of flow control is that pressure difference in front and rear of the constriction against the inflow works to the flow control spring with constricted upstream pressure applied to side and constricted downstream pressure applied to side of flow control spool. In Fig. 1, if inflow surpasses Q0, pressure difference in front and rear of the flow control spool becomes larger than load at mounting in flow control spring. This allows opening P to T to open and surplus is discarded flow in the section marked as out of the flow control valve for which the motor speed is to be kept constant in the range between and .
• The motor mounts electromagnetic proportional variable flow control valve. The flow control valve of this type makes it possible to change continuously the plateau between and as in Fig. 2 to constant speed of the motor in the range between ’ and ’ altering the command current.
Lep SC4608030-0EN
Issued 03-07
Copyright © 8030-46
4. Operation of Forward / Reverse Changeover Valve [1] When ON-OFF solenoid for changeover valve is demagnetized • When ON-OFF solenoid for changeover valve [1] is demagnetized, pressure oil from the pump is shut off by ON-OFF changeover valve [2] allowing port C to lead to the tank circuit. • This allows the changeover spool [3] to be pushed to the right by the changeover spool spring [4] and the motor port MA opens to let the pressure oil flow in and as a result the motor makes forward rotation (CW).
Lep SC4608030-0EN
[2] When ON-OFF solenoid for changeover valve is magnetized • When ON-OFF solenoid for changeover valve [1] is magnetized, ON-OFF change over valve [2] switches over and pressure oil from the pump enters in the port C to let it flow into the chamber D. • Pressure oil in the chamber D overcomes the changeover spool spring [4] to push the changeover spool [3] to the left. This allows the motor port MB to open and pressure oil flows in and as a result the motor makes reverse rotation (C.C.W.).
Issued 03-07
9002
Copyright ©
Section 9002 UPPERSTRUCTURE, TURNTABLE AND COUNTERWEIGHT
CNH
Lep SM4609002-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 9002-2
TABLE OF CONTENTS SPECIAL TORQUE SETTINGS ..................................................................................................................................... 2 SPECIFICATIONS ......................................................................................................................................................... 2 UPPERSTRUCTURE .................................................................................................................................................... 3 Inspection ................................................................................................................................................................... 3 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 6 COUNTERWEIGHT ..................................................................................................................................................... 10 Description ............................................................................................................................................................... 10 Removal .................................................................................................................................................................... 11 Installation ................................................................................................................................................................. 12
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
SPECIAL TORQUE SETTINGS See Section 1002.
SPECIFICATIONS Weight ................................................................................................................................................... See Section 1002
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-3
UPPERSTRUCTURE Inspection STEP 1
STEP 5
Checking the turntable If the upperstructure does not revolve properly or creaks, this shows that the turntable is worn or damaged. If the upperstructure pauses before revolving, this shows that the crown wheel of the turntable is damaged. When an operator is working with the machine, he must pay attention to any unusual noises which could indicate turntable wear. If the operator hears unusual noises and if the upperstructure pauses before revolving, he must carry out the following inspection.
STEP 2 Park the machine on hard, level ground. Lower the attachment to the ground.
STEP 3 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 4
1 2
3 CS02C505
Remove the three screws (1) that fasten the access door (2) to the machine. Remove the access door (2). Remove and discard the seal (3) from the access door (2).
STEP 6
!
1 CI00F500
Remove the screws (1) that attach the lower housing to the machine and remove the lower housing.
WARNING: If your hand is in the access port of the crown wheel when the upperstructure is revolving, you could get seriously injured. Before applying grease by hand on the crown wheel, always check that the bucket or the tool is placed on the ground and that the engine is shut down.
Ask an assistant to help you operate the swing mechanism, check for scratches, missing teeth, scaling, cracks or other damage on the crown wheel using a pocket light. In case of damage, refer to "Removing the upperstructure" and change the turntable of the upperstructure.
STEP 7 Install a new seal (3) on the access door and install the access door (2) on the machine using screws (1).
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-4
STEP 8
STEP 4
Install the lower housing on the machine using screws and plate washers.
Removal STEP 1
JS00163A1
Park the machine on hard, flat ground. Lower the attachment to the ground.
STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).
STEP 3
1 2
FUEL TANK LOWER ACCESS PANEL HYDRAULIC RESERVOIR LOWER ACCESS PANEL
Remove the lower access door of the fuel reservoir (1) located in front and on the right. Place a container beneath the drain valve of the fuel reservoir. Open the drain valve and drain the fuel. NOTE: See Section 1002 for the capacity of the fuel reservoir.
STEP 5 Open the left-hand side door. Disconnect the earth cable (1) from the battery. Close the LH side door.
Remove the lower access plate from the hydraulic reservoir (2). Place a container beneath the drain valve of the hydraulic reservoir. Open the drain valve and drain the hydraulic fluid into the container. NOTE: See Section 1002 for the capacity of the hydraulic reservoir and the capacity of the entire system.
STEP 6 Refer to Section 8006 and remove the hydraulic swivel.
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-5
STEP 7
STEP 14
Refer to Section 9003 and remove the bucket, the dipper and the boom.
Remove the screws (3) that attach the turntable to the undercarriage. Carefully disengage the turntable from the undercarriage by lifting it. Place the turntable on suitable supports in order to protect the surfaces of the turntable from any damage. Remove the lifting equipment from the lifting rings and disassemble the lifting rings from the turntable.
STEP 8 Refer to page 10 in this Section and remove the counterweight.
STEP 9 Install lifting rings at the rear of the upperstructure. Connect a suitable lifting device to these lifting rings and to the lifting rings located at the front of the upperstructure, above the boom brackets. Use the total movement of the lifting device. NOTE: Refer to specifications on page 2 for the weight of the upperstructure. Make sure that the lifting equipment has sufficient lifting and support capacity for the upperstructure.
STEP 10
1
4 CD01K066
Using paint or another marking product, make marks on the upperstructure, turntable (4) and the undercarriage, to facilitate re-assembly of the upperstructure and the turntable. NOTE: The numbers within brackets in the following steps refer to the schematic on page 6.
STEP 11 Remove the screws (1) as well as the flat washers (2) of the upperstructure turntable (4).
STEP 12 Carefully disengage the upperstructure from the undercarriage by lifting it. Place the upperstructure on suitable supports in order to protect the swing reduction gear pinion from any damage.
STEP 13 Install lifting rings on the turntable (4). Connect suitable lifting equipment to the lifting rings. Use the total movement of the lifting device. NOTE: Refer to specifications on page 2 for the weight of the turntable.
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-6
Installation Turntable 2 1
2 4
1
2 1
3 CS02C506
1 2 3 4
SCREW FLAT WASHER SCREW TURNTABLE
STEP 1
STEP 3
Clean the surfaces of the undercarriage and the turntable.
Position the turntable (4) on the undercarriage. Align the marks on the turntable (4) and on the undercarriage. Remove the lifting equipment and remove the lifting rings from the turntable.
NOTE: The numbers within brackets in the following steps refer to the diagram of the turntable.
STEP 2 Install lifting rings on the turntable (4) and connect a suitable lifting device to these rings. Use the total movement of the lifting device. NOTE: Refer to specifications on page 2 for the weight of the turntable.
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-7
STEP 4
STEP 10 Refer to Section 9003 and reassemble the boom, the dipper and the bucket on the machine.
STEP 11 Make sure that the drain valve of the hydraulic reservoir is closed. For filling the reservoir refer to the chapter "Filling the reservoir" in the operator’s manual.
1
NOTE: See Section 1002 for the capacity of the hydraulic reservoir and the capacity of entire system.
4
STEP 12
CD01K066
Coat the screw threads (3) with Loctite 262. Install the screws (3) to attach the turntable (4) to the undercarriage. Tighten the screws (3) to the torques specified on page 2.
STEP 5 Connect a suitable lifting device to the lifting rings located in front of the upperstructure, on top of the boom brackets, as well as to the rings installed on the upper frame behind the upperstructure. NOTE: Refer to specifications on page 2 for the weight of the upperstructure. Make sure that the lifting equipment has sufficient lifting and support capacity for the upperstructure. NOTE: When the upperstructure is lowered and touches the turntable and the crown wheel, make sure that the swing reduction gear pinion engages perfectly with the teeth on the upperstructure crown wheel.
STEP 6 Carefully install the upperstructure in position on the turntable. Align the marks on the upperstructure and on the turntable. Check that the mounting ports of the upperstructure are aligned with those of the turntable. NOTE: The numbers within brackets in the following steps refer to the schematic on page 6.
STEP 7 Coat the screw threads (1) with Loctite 262. Install the screws (1) with flat washers (2) in the turntable and the upperstructure to fasten the upperstructure en position. Tighten the screws (1) to the torques specified on page 2.
STEP 8
1 2
FUEL TANK LOWER ACCESS PANEL HYDRAULIC RESERVOIR LOWER ACCESS PANEL
Install the access door (2) under the hydraulic reservoir, as well as the access door (1) under the fuel reservoir.
STEP 13
STEP 9
Make sure that the drain valves of the fuel and hydraulic reservoirs are closed, fill the reservoirs (see the operator’s manual).
Refer to Section 8006 and reassemble the hydraulic swivel.
NOTE: See Section 1002 for the capacity of the fuel reservoir and the hydraulic reservoir.
Remove the lifting device then remove the lifting rings.
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-8
STEP 14
STEP 17 Apply grease by hand on the crown wheel.
STEP 18 Start the engine and turn the upperstructure by one eighth of a turn. Shut down the engine.
STEP 19 Apply grease again by hand on the crown wheel.
STEP 20 Repeat the operation until all teeth of the turntable are properly lubricated. NOTE: Refer to the specifications on page 2 for the quantity of grease to be applied. Open the left-hand side door. Reconnect the earth cable (1) to the battery. Close the LH side door.
STEP 21
STEP 15 Refer to page 10, "Installing the counterweight" and put the counterweight back in place.
!
WARNING: If your hand is in the access port of the crown wheel when the upperstructure is revolving, you could get seriously injured. Before applying grease by hand on the crown wheel, always check that the bucket or the tool is placed on the ground and that the engine is shut down. CD01K066
Apply grease to the grease fittings on the turntable. Install a new seal ring.
STEP 16
1 2
3 CS02C505
Remove the three screws (1) that fasten the access door (2) to the upperstructure. Remove the access door (2). Scrap the seal (3).
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-9
STEP 22 Install the access door with the seal, on the machine. Fasten it in position with the three screws and the locking washers.
STEP 23
CI00F500
Install the lower housing under the machine using screws and washers.
Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-10
COUNTERWEIGHT Description
1
5
4
3
2
09-009-0A
1 2 3
COUNTERWEIGHT SCREW WASHER
Lep SM4609002-0EN
4 5
SHIM INSULATING MATERIAL
Issued 09-07
Copyright © 9002-11
Removal
STEP 3
NOTE: The numbers within brackets in the following steps refer to the schematic on page 10.
STEP 1
Attach a suitable lifting device to the lifting rings of the counterweight (1). Use the total movement of the lifting device. NOTE: Refer to the specifications on page 2 for the weight of the counterweight.
STEP 2
Remove the screws (2) and the flat washers (3) that fasten the counterweight (1) to the undercarriage. Raise the counterweight (1) and remove it from the machine. Place it on flat ground. Remove the lifting equipment.
STEP 4 Remove the shims (4) from the undercarriage anchorage points. NOTE: Count the number of shims (4), remove them from each anchorage point. Keep each set of shims (4) to facilitate reassembly.
STEP 5 Check the state of the insulating material (5) installed on the counterweight. Change the insulating material if it is damaged. Lep SM4609002-0EN
Issued 09-07
Copyright © 9002-12
Installation
STEP 4
NOTE: The numbers within brackets in the following steps refer to the schematic on page 10.
STEP 1
Install the screws (2) as well as the flat washers (3) to attach the counterweight (1). Tighten to the torques specified on page 2. Attach a suitable lifting device to the lifting rings of the counterweight (1). NOTE: Refer to the specifications on page 2 for the weight of the counterweight.
STEP 5 Remove the lifting device from the lifting rings of the counterweight (1).
STEP 2 Install the same number of shims (4) as those removed in step 4 of removal, at each anchorage point of the counterweight on the undercarriage.
STEP 3
Move the counterweight (1) into position on the undercarriage. Align the ports of the counterweight with those on the undercarriage.
Lep SM4609002-0EN
Issued 09-07
Copyright ©
9003
Section 9003 BOOM, DIPPER AND BUCKET
CNH
Lep SM4609003-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 9003-2
TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................................... 2 BUCKET.......................................................................................................................................................................... 3 Description .................................................................................................................................................................. 3 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 4 Shimming the bucket ................................................................................................................................................. 5 Removal and installation of Bucket Yoke and Connecting rod .................................................................................. 6 DIPPER ........................................................................................................................................................................... 8 Description .................................................................................................................................................................. 8 Removal ..................................................................................................................................................................... 9 Installation .................................................................................................................................................................. 9 BOOM ........................................................................................................................................................................... 11 Description ................................................................................................................................................................ 11 Removal ................................................................................................................................................................... 12 Installation ................................................................................................................................................................ 13
SPECIFICATIONS See Section 1002
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-3
BUCKET Description 13
21
14
23
20 17 20
20 17 20
16 13 10
15
21 14
19
22
9
15
4 18 18 22
9
12
19 11
6
7 24 2 3
1
24
JS0127B
1 2 3 4 5 6 7 8 9 10 11 12
LOCKING PIN PIN BUCKET YOKE LOCKING PIN PIN DUST SEAL GREASE FITTING NUT SCREW PIN SHIM
Lep SM4609003-0EN
13 14 15 16 17 18 19 20 21 22 23 24
CONNECTING ROD GREASE FITTING BUSHING BUSHING SHIM DUST SEAL DUST SEAL LINKAGE SEAL LINKAGE SEAL LINKAGE SEAL LINKAGE SEAL RETAINING RING
Issued 09-07
Copyright © 9003-4
Removal
STEP 4
STEP 1 Place the bucket flat on flat, level ground. Operate the attachment controls so that the dipper/bucket connecting pin is not under load from the weight of the dipper. Shut down the engine.
STEP 2
Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.
Installation STEP 1 Make sure the bucket is in a stable position. Remove the retaining rings and pins.
STEP 2
STEP 3
Remove the bucket pins.
Lep SM4609003-0EN
Install the linkage seals on the dipper bushing shoulders. Change them if necessary. Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine and remove the starter switch key.
Issued 09-07
Copyright © 9003-5
STEP 3
Shimming the bucket The machine is equipped with a bucket play adjusting system which eliminates play that develops at the bucket/dipper linkage due to wear. This system delays the effects of wear and gives longer life to bushings and pins. NOTE: Incorrect adjustment of the play can cause friction, abnormal noises or excess play and damage the O-rings.
Adjusting the play Place the bucket flat, lying on the ground.
1 J Install the dipper/bucket linkage pin and then install the retaining pin and ring. Start the engine. Bring the bucket rod into its housing, stop the engine and remove the starter switch key.
STEP 4
2
CD00E121
Check the play (J) between the dipper and the bucket lug. If the play (J) exceeds 4 mm, remove the four screws and the cap (1), then the shims (2). Use the shims (2) as a feeler gauge and calculate the number of shims necessary to eliminate the play (J). Install the necessary number of new shims. Reinstall the cap (1) and the four screws. NOTE: When the screws on the cap (1) are tightened, the inner bushing moves towards the dipper and the play is eliminated. Install the connecting rod/bucket linkage pin and then install the retaining pin and ring. Push the seals back into their housings. Adjust the dipper/bucket shimming. See "Shimming the backhoe bucket". Grease the linkage pins.
Lep SM4609003-0EN
IMPORTANT: It is recommended to maintain a play of about 1.2 mm. If the play is insufficient, it may cause wear by friction or seizing. IMPORTANT: The inner bushing has a stud which prevents the bushing from turning. The cap (1) has an orifice in its inner surface. Make sure that the stud is inserted in that orifice when the cap is installed (1).
Issued 09-07
Copyright © 9003-6
Removal and installation of Bucket Yoke and Connecting rod
STEP 3
Remove the bucket. (For details, see page 4 "Removal and Installation of Bucket".)
STEP 1
Place the bucket yoke (1) parallel to the ground.
STEP 2
Use the bar hammer (1) and the holding-up bar (2) to push out the pin (3), and remove the bucket yoke (4).
Remove double nuts (1) and (2), and then pull out bolts (3) and (4).
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-7
STEP 4
Use a bar hammer (1) and the holding-up bar (2) to push out the pin (3), and remove connecting rod (4) and (5). If the pin is difficult to pull out, it is being loaded. When pulling out a pin, take care not to damage the installed O-ring and dust seal. When installing parts, clean the pin and pin opening of each part, and firmly rub them with grease. NOTE: When installing proceed in the reverse order from removal. Change linkage seals and bushing, if necessary.
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-8
DIPPER Description 5 3 1 2 6
7 10
8 6
7
13
4
9
7 12 8 11
9
12
JS01274C
1 2 3 4 5 6
WASHER SCREW PIN DIPPER BOOM DUST SEAL
Lep SM4609003-0EN
7 8 9 10 11 12
BUSHING BUSHING BUSHING SHIM SEAL SEAL
Issued 09-07
Copyright © 9003-9
Removal
STEP 6
STEP 1 Remove the bucket, the connecting rods and the yoke, see page 4.
STEP 2 Start the engine, retract the dipper cylinder rod and lower the attachment to the ground. Shut down the engine.
STEP 3 Remove the bucket cylinder and disconnect the dipper cylinder rod from the dipper, see Section 8005. Attach the dipper cylinder rod to the boom.
STEP 4
Use a bar hammer (1) and the holding-up bar (2) to push out the pin (3) and remove the arm (4). If the pin is difficult to pull out, it is being loaded. When pulling out a pin, take care not to damage the installed O-ring and dust seal. When installing parts, clean the pin and pin opening of each part, and firmly rub them with grease.
STEP 7 Start the engine, move the machine backwards to separate the dipper from the boom. Lower the boom to the ground and shut down the engine.
STEP 8 Lower the dipper to the ground and remove the lifting equipment from the dipper. Attach a suitable lifting device to the dipper. Take up any slack on the lifting slings, since the dipper has to be supported before lifting.
STEP 5
STEP 9 Remove and scrap the dust seals. NOTE: Perform step 10 only if the bushings have to be changed.
STEP 10 Remove the bushings from the dipper or from the boom, using a hammer and a suitable drift on the outer diameter of the bushing.
Installation NOTE: Perform step 1 only if the bushings have been removed.
STEP 1 Using a suitable sleeve, install the bushings.
STEP 2 Remove the screw (1).
Install new dust seals on the dipper.
STEP 3 Attach a suitable lifting device to the dipper. Move the dipper into position near the machine.
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-10
STEP 4 Start the engine and move the machine forwards so that the boom is aligned with the dipper. Check the alignment of the pin bores on the boom and the dipper. Shut down the engine.
STEP 5
3
Install the pin (3) and the lock bolt (1).
STEP 6 Using a set of feeler gauges, check that the play between the boom and the dipper is 4.5 to 5.5 mm . If necessary, remove the pin (3) and add one or more shims as required to arrive at the correct clearance. Install the pin (3).
STEP 7 Remove the lifting device from the dipper.
STEP 8 Connect the dipper cylinder rod to the dipper and install the bucket cylinder, see Section 8005.
STEP 9 Install the bucket, see page 4.
STEP 10 Bleed the cylinders, see Section 8000.
STEP 11 Grease the linkages.
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-11
BOOM Description 6 7
5 7
6 5
2 3
4
1
JS01275B
1 2 3 4 5 6 7
WASHER SCREW PIN BOOM SHIM DUST SEAL BUSHING
Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-12
Removal
STEP 7
STEP 1 Remove the dipper, see page 9.
STEP 2 Start the engine and lower the boom to the ground. Shut down the engine.
STEP 3 Remove the dipper cylinder, see Section 8005. Do not remove the vacuum pump from the hydraulic reservoir.
STEP 4 Disconnect the boom cylinder rods from the boom, see section 8005
STEP 5
Wrap a nylon sling (1) around the pin that was installed in step [4], and fix it with the crane.
STEP 8
Remove the grease nipple (1) and inser a batten (2) to the root of the boom cylinder.
STEP 6 Remove the lock bolt (1).
STEP 9
Install the pin (1) that was removed in section 8005. Install the bolt (3) with 2 lock nuts (2) and also install the securing ring (4).
Lep SM4609003-0EN
Use a 24-mm slide hammer (1) to remove the pin (2).
Issued 09-07
Copyright © 9003-13
STEP 10
STEP 13
Disconnect all the hoses. Mark the hoses and pipes so that the connectors match at the time of assembly. Use caps or plugs to cover the hoses and pipes to prevent the entry of water, dust or dirt. Clean the hoses and pipes by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
Remove and scrap the boom dust seals (6).
STEP 11 Disconnect the boom cylinder rods from the boom, see Section 8005. NOTE: The numbers in brackets in the following steps refer to the drawing on page 11.
STEP 12
NOTE: Perform step 12 only if the bushings (7) have to be changed.
STEP 14 Remove the bushings (7) from the boom, using a hammer and a suitable drift on the outer diameter of the bushing.
Installation NOTE: Perform step 1 only if the bushings (7) have been removed.
STEP 1 Using a suitable sleeve, install the bushings (7) on the boom.
STEP 2 Install new dust seals (6) on the boom.
STEP 3
Reverse the machine and remove the boom (1).
Attach a suitable lifting device to the boom. Raise the boom and move it into position, check the alignment of the boom and chassis orifices.
STEP 4
3
Install the pin (3) and the lock bolt (1). Lep SM4609003-0EN
Issued 09-07
Copyright © 9003-14
STEP 5 Using a set of feeler gauges, check that the play between the boom and the chassis is 3.5 to 5.5 mm. If necessary, remove the pin (3) and add one or more shims (5) as required to arrive at the correct clearance. Install the pin (3).
STEP 6 Connect the boom cylinder rods to the boom, see Section 8005.
STEP 7 Start the vacuum pump and remove the plugs from the hoses. Connect the supply hoses at the bottom of the boom. Stop the vacuum pump.
STEP 8 Install the dipper cylinder on the boom, see Section 8005.
STEP 9 Install the dipper and the bucket, see page 8.
STEP 10 Bleed the cylinders, see Section 8000.
STEP 11 Grease the linkages.
Lep SM4609003-0EN
Issued 09-07
Copyright ©
Section
SEAT AND SAFETY BELT
CNH
Lep SM4609004-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
9004
9004
Copyright © 9004-2
TABLE OF CONTENTS SPECIFICATIONS ......................................................................................................................................................... 2 OPERATOR'S SEAT ...................................................................................................................................................... 3 Description ................................................................................................................................................................. 3 Removal ..................................................................................................................................................................... 4 Installation .................................................................................................................................................................. 7 SAFETY BELT ............................................................................................................................................................... 8 Removal ..................................................................................................................................................................... 8 Installation .................................................................................................................................................................. 8
SPECIFICATIONS Weight of the operator's seat.................................................................................................................. 46 kg (101.41 lb)
Lep SM4609004-EN
Issued 09-07
Copyright © 9004-3
OPERATOR'S SEAT Description
1
10
9 6
4
5
3
8
7 2
CS02A504
1 2 3 4 5
OPERATOR'S SEAT MASK BOOT RAIL REAR CONTROL ARM BRACKET
Lep SM4609004-0EN
6 7 8 9 10
SHOCK ABSORBER BRACKET FRONT CONTROL ARM BRACKET CYLINDER BULB
Issued 09-07
Copyright © 9004-4
Removal
STEP 5
STEP 1
2 1 CD00G049
JS00163A1
Park the machine on hard, flat ground. Lower the tool to the ground.
Loosen and remove the screw (1) that retains the function cancellation lever (2). Remove the lever.
STEP 6
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 3 Move the operator's seat as far forward as possible.
STEP 4
CD00G050
Loosen and remove the three screws that hold the inner cab access bar. Remove the access bar.
STEP 7 1 CD00G048
Lift the boot. Loosen and remove the four screws (1) from the front portion of the control arm. NOTE: Steps 5 to 7 are to be carried out only for the LH control arm.
2 1
CD00G051
Label and disconnect the electrical connectors (1), remove the compartment control casing assembly (2).
Lep SM4609004-0EN
Issued 09-07
Copyright © 9004-5 NOTE: For the LH control arm, do not carry out step 8.
STEP 11
STEP 8
Lift the upper portion of the control arm and position it to the side.
STEP 12
CD00G066
Remove the trim then remove the air-conditioning box using the four screws. Remove the latter. CD00G117
STEP 9
Loosen and remove the two upper screws as well as the two lower screws that hold the front portion of the control arm.
1
1
NOTE: For the RH control arm, do not carry out steps 13 and 14.
STEP 13
1 1 CD00G052
Loosen and remove the four screws (1) from the rear portion of the control arm.
STEP 10 CD00G118
Loosen and remove the screws that hold the LH side portion of the control arm.
1
CD00G053
Loosen and remove the two screws (1) that hold the arm angle adjustment lever, then remove the lever.
Lep SM4609004-0EN
Issued 09-07
Copyright © 9004-6
STEP 14
STEP 16
1
1 1
CD00G058
CD00G120
Loosen from the LH side, the rod (1) that links the function cancellation lever to the safety bar (2).
Loosen and remove the two front retaining screws (1) of the control arm to the front seat bracket.
STEP 15
STEP 17
LH side
2 1 1 1
CD00G121 CD00G059
RH side
Loosen and remove the two rear retaining screws (1) of the control arm to the rear seat bracket.
2
1
CD00G119
Loosen and remove the four screws that fasten the plate (1) to the bracket (2).
Lep SM4609004-0EN
Issued 09-07
Copyright © 9004-7
STEP 18
STEP 20
1
CD00G127
Move the LH control arm (1) on the cab side, keep it in this position using suitable lifting equipment. NOTE: For the RH control arm, position it behind the cab.
STEP 19
CD00G123
Remove the carpet, loosen then remove the eight retaining screws from the seat. Remove the seat from the cab, with the help of an assistant. NOTE: The seat weighs 46 kg (101.41 lb).
Installation To install, proceed in the reverse order from that of removal.
1
1 1 1 CD00G122
Remove the trim in front of the seat using the four screws (1).
Lep SM4609004-0EN
Issued 09-07
Copyright © 9004-8
SAFETY BELT Removal
STEP 4
STEP 1
2
CD00G125
JS00163A1
Park the machine on hard, flat ground. Lower the tool to the ground.
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
Loosen and then remove the screw (2) and the washer. Remove the inertia-reel.
Installation To install, proceed in the reverse order from that of removal.
STEP 3
1
CD00G124
Loosen then remove the retaining screw (1) and the washer. Remove the seat fastener.
Lep SM4609004-0EN
Issued 09-07
Copyright ©
Section 9005
9005
CAB AND CAB EQUIPMENT
CNH
Lep SM4609005-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 9005-2
TABLE OF CONTENTS
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
CAB ............................................................................................................................................................................... 3 Removal .................................................................................................................................................................... 3 Installation ................................................................................................................................................................. 6 HEATER ........................................................................................................................................................................ 9 Description ................................................................................................................................................................ 9 Removal .................................................................................................................................................................. 10 Installation ............................................................................................................................................................... 11 WINDSHIELD WIPER MOTOR ................................................................................................................................... Description .............................................................................................................................................................. Removal .................................................................................................................................................................. Installation ...............................................................................................................................................................
Lep SM4609005-0EN
13 13 14 15
Issued 09-07
Copyright © 9005-3
CAB Removal
STEP 7 Remove the radio, if fitted.
STEP 1
STEP 8
JS00163A
Park the machine on hard, flat ground. Lower the tool to the ground.
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
Remove the trim panel at the rear of the cab, taking care to disconnect the connector for the cigarette lighter and the solar radiation detector.
STEP 9
STEP 3
2
1 CD00G004
Open the left-hand side doors. Disconnect the earth cable (1) from the battery. Close the doors.
Remove the two electronic boxes (1) and (2), see Section 4003.
STEP 4 Fold the operator's seat-back down and move the seat as far as possible.
STEP 5 Remove the floor mat from the cab.
STEP 6 Remove the thrust bar on the left-hand side of the cab.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-4
STEP 10
STEP 14 4
3 5
CD00G006
Disconnect the windshield washer pipe and remove the retaining clip.
STEP 15 Remove the windshield wiper motor, see page 13 in this section.
STEP 16 Remove the relays and the relay retaining plate (3).
Remove the upper right-hand side trim panel and remove the display.
STEP 11
STEP 17
Remove the controller brackets (4) and (5).
STEP 12
1
1
2
CD00G005
Remove the screws (1) which fasten the rear ventilation and remove the two conduits.
STEP 13 Remove the connectors (2) at the rear of the cab.
Remove the pollen filter guard, remove the pollen filter and remove the pollen filter conduit.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-5
STEP 18
STEP 20
Remove the working light from the top of the cab. Retract the radio aerial. Install suitable lifting rings on the top of the cab. Install lifting equipment.
STEP 19 Remove the screws and washers which fasten the cab to the frame. NOTE: Keep away from the cab while it is being lowered. Make sure that the cab is not damaged during lifting or lowering. Room for manoeuvre is very limited at the rear, on the sides and inside the cab.
Using the lifting equipment, carefully raise the cab until it is completely away from the machine, then lower it to the ground.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-6
Installation NOTE: Keep away from the cab while it is being lowered. Make sure that the cab is not damaged during lifting or lowering. Room for manoeuvre is very limited at the rear, on the sides and inside the cab.
STEP 1
Install suitable lifting rings on the top of the cab. Using suitable lifting equipment, raise the cab. Guide the cab so that it is correctly aligned with the mounting studs and orifices in the upperstructure frame.
STEP 2 Install the screws and washers which fasten the cab to the frame.
STEP 3 Install the working light on the top of the cab.
STEP 4 Install the windshield wiper motor, see page 13 in this section.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-7
STEP 5
STEP 9
Use the screws to install the display and connect it to the electrical harness.
STEP 6
1 Install the electronic control box support brackets.
2
STEP 10 Connect the electrical harnesses together.
STEP 11
Install the pollen filter and the pollen filter conduit. Using screws (1), fasten the pollen filter housing (2) to the cab.
STEP 7 Reconnect the blower motor conduit to the ventilation conduit at the front of the cab. Reconnect the ventilation conduit at the rear of the cab. CD00G004
STEP 8
Install the relays and the two controllers, see Section 4003. .
CD00G006
Connect the windshield washer pipes together and attach the retaining clip. Install the trim panel at the rear of the cab, taking care to reconnect the cigarette lighter connector and the solar radiation detector.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-8
STEP 12 Install the radio, if fitted.
STEP 13 Install the access bar, using screws and washers.
STEP 14 Install the floor mat.
STEP 15
Open the left-hand side doors. Reconnect the battery cable (1) to the battery. Close the doors.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-9
HEATER Description
12
1
3 1
10
4
9
5
6 11 8 7 2
CS02C514
1 2 3 4 5 6
CAB REAR VENTILATION CONDUIT CAB LOWER VENTILATION CONDUIT PLUG POLLEN FILTER CONDUIT SCREW
Lep SM4609005-0EN
7 8 9 10 11 12
HEATER HOSE RETAINING CLIP UNION UNION HEATER ASSEMBLY CONTROL BLOCK
Issued 09-07
Copyright © 9005-10
Removal
STEP 5
STEP 1
!
WARNING: Boiling cooling fluid can spurt out when the radiator cap is removed. To remove the cap, proceed as follows: Wait until the system has cooled down and then turn the cap slightly and wait for all the pressure to be released. You can be seriously scalded if the radiator cap or expansion reservoir cap is removed too quickly. For checking and maintenance of the cooling system, refer to the maintenance instructions.
Make sure that the radiator has cooled down and remove the radiator cap. JS00163A
Park the machine on hard, flat ground. Lower the tool to the ground.
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 3
Open the left-hand side doors. Disconnect the earth cable (1) from the battery. Close the doors.
STEP 4 Raise the engine hood and lock it in the raised position.
STEP 6 Use a container of suitable capacity and drain the oilcooler (see Section 2001).
STEP 7 Remove the operator's seat from the cab (see Section 9004).
STEP 8
Install the trim panel at the rear of the cab, taking care to disconnect the connector for the cigarette lighter and the solar radiation detector.
STEP 9 Disconnect the electric blower supply harness.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-11
STEP 10
Installation
NOTE: The numbers within brackets refer to the schematic on page 9.
NOTE: The numbers within brackets refer to the schematic on page 9.
STEP 1 Install the heater in the cab, using the screws (6), brake washers and flat washers.
8
STEP 2
8 7
7
4 CD00G044
Unscrew the hose clips (8) and disconnect the heater hoses (7).
STEP 11 Remove the ventilation conduits (1) and (2) from the cab.
STEP 12
Install the conduit (5), the pollen filter (4) and the pollen filter guard.
STEP 3 Install the heater ventilation conduits (1) and (2).
STEP 4 4
8
8 Remove the pollen filter guard, remove the filter (4) and remove the conduit (5).
7
7
STEP 13 Remove the screws (6) that secure the heater to the cab. Remove the heater from the cab.
Lep SM4609005-0EN
CD00G044
Install the heater hoses (7) and tighten the retaining clips (8).
Issued 09-07
Copyright © 9005-12
STEP 5 Connect the blower supply electrical harness.
STEP 6
STEP 10 Start the engine and run it at idle speed for one minute. Shut down the engine.
STEP 11 Add cooling fluid according to requirement in the expansion reservoir.
!
WARNING: Boiling cooling fluid can spurt out when the radiator cap is removed. To remove the cap, proceed as follows: Wait until the system has cooled down and then turn the cap slightly and wait for all the pressure to be released. You can be seriously scalded if the radiator cap or expansion reservoir cap is removed too quickly. For checking and maintenance of the cooling system, refer to the maintenance instructions.
Install the trim panel at the rear of the cab, taking care to reconnect the cigarette lighter connector and the solar radiation detector.
STEP 12
STEP 7
Start the engine and run it at maximum speed until it reaches normal working temperature.
Install the operator's seat in the cab (see Section 9004).
STEP 8 Pour suitable cooling fluid in the radiator (see Section 2001).
STEP 9
STEP 13 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 14 Let the oil-cooler cool.
STEP 15 When the radiator feels cold, remove the caps from the radiator and the expansion reservoir. Top up if necessary.
STEP 16 Close the left-hand side doors.
Open the left-hand side doors. Reconnect the earth cable (1). Close the doors.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-13
WINDSHIELD WIPER MOTOR Description
4 11
9 8
10
2 1 7 6 3
5
CI00G502
1 2 3 4 5 6
PROTECTIVE FLAP WINDSHIELD WIPER ARM NUT WINDSHIELD WIPER MOTOR RUBBER CAP NUT
Lep SM4609005-0EN
7 8 9 10 11
FLAT WASHER PLASTIC SUPPORT SCREW ELECTRICAL HARNESS SCREW
Issued 09-07
Copyright © 9005-14
Removal
STEP 6
STEP 1
Note the position of the windshield wiper arm (2). Remove the windshield wiper arm (2) from the windshield wiper motor (4) by pulling it off the windshield wiper motor shaft.
STEP 7 Remove the rubber cap (5).
STEP 8 Remove the nuts (6), washer (7) and plastic support (8) from the windshield wiper motor shaft.
STEP 9 JS00163A
Park the machine on hard, flat ground. Lower the tool to the ground.
STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.
STEP 3
CD00G133
Remove the upper right-hand trim.
STEP 10 A A Open the left-hand side doors. Disconnect the earth cable (1) from the battery. Close the doors.
A
STEP 4 NOTE: The numbers within brackets refer to the schematic on page 13. From the front of the cab, raise the protective flap (1) located on the lower portion of the windshield wiper arm (2).
STEP 5 Remove the nut (3).
CD00G134
Remove the lower front trim inside the cab, by the screw(s) (A).
STEP 11 Disconnect the electrical harness (10) from the windshield wiper motor (4).
STEP 12 Remove the screws (9) and (11) from the windshield wiper motor. Remove the windshield wiper motor.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-15
Installation
STEP 8
NOTE: The numbers within brackets refer to the schematic on page 13.
Turn back the flap (1) located on the lower portion of the windshield wiper arm (2).
STEP 1
STEP 9
Place the windshield wiper motor (4) in position on the cab bracket. Connect the windshield wiper motor connector (4) to the electrical harness (10).
STEP 2 Install the windshield wiper motor (4) on the cab pillar, using the screws (9) and (11).
STEP 3
Open the left-hand side doors. Connect the earth cable (1). Close the doors.
STEP 10 Switch on the windshield wiper motor and check that everything is working correctly.
CD00G134
Install the right-hand front trims in the cab using the screws.
STEP 4 Install the support (8), washer (7) and the two nuts (6). Tighten the nuts.
STEP 5 Install the rubber cap (5).
STEP 6 Install the windshield wiper arm (2) on the windshield wiper motor shaft (4), positioning the windshield wiper arm (2) in the same position as was noted at disassembly.
STEP 7 Install the nut (3) on the windshield wiper motor shaft. Tighten the nut.
Lep SM4609005-0EN
Issued 09-07
Copyright © 9005-16
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... ..........................................................................................................................................................................................
Lep SM4609005-0EN
Issued 09-07
Copyright ©
Section 9007 AIR CONDITIONER
9007
DISASSEMBLY AND ASSEMBLY
CNH
Lep SM4609007-0EN
Copyright © 2007 CNH France S.A. Printed in France September 2007
Copyright © 9007-2
TABLE OF CONTENTS SPECIFICATIONS ........................................................................................................................................................... 2 SPECIAL TORQUE.......................................................................................................................................................... 3 AIR CONDITIONER ......................................................................................................................................................... 4 Description ................................................................................................................................................................... 4 Disassembly and assembly .......................................................................................................................................... 5
SPECIFICATIONS Capacity of the system ............................................................................................................................... 1.350 ± 0.05 kg Type of cooler ................................................................................................................................................ HFC (R) 134a Receiver dryer max. setting pressure of the system with full gas load................................................................. 3.14 Mpa Table 1 Replacement part
Oil level adjustment
Compressor
Measure the oil volume in compressor that is removed. Remove all the oil except that remaining in the compressor that was removed from the brand new compressor. Example: If 30 cc of oil remains in the removed compressor (for a SD7H13WM7359 compressor), remove 105 cc from the brand new compressor. (135 cc - 30 cc = 105 cc)
Evaporator
Refill 40 cc.
Condenser
Refill 40 cc.
Receiver dryer
Refill 20 cc.
NOTE: The oil type is different according to compressors. Refer to the nameplate attached to the compressor, which has indications for the oil type. NOTE: Before starting the operation, stop the engine and turn off the power for air conditioner related devices. Avoid water or dust from entering the refrigerating circuits. In addition, do not leave the piping unattached from the machine. Avoid conducting piping removal or fitting work under rainy conditions. When the work is completed, check that the faulty parts have been fully repaired by running the air conditioner.
Lep SM4609007-0EN
Issued 09-07
Copyright © 9007-3
SPECIAL TORQUE Table 2 Pipe fastening section
Tightening torque N•m
1
D hose and compressor (M8 bolt)
20 to 30
2
S hose and compressor (M8 bolt)
20 to 30
3
D hose and condenser (1/2 inch nut)
20 to 25
4
Condenser and L hose (L pipe) (8 mm nut)
12 to 15
5
L hose (L pipe) and receiver dryer (M 6 bolt)
8 to 12
6
S hose, L hose and expansion valve (M6 x P1.25)
8 to 12
Table 3 Category
Type
Nominal diameter (mm)
Pitch (mm)
Tightening torque N•m
Bolt
7T
M6
1.0
8 to 12
M8
1.25
20 to 30
9T
Nut
Pipe diameter
M10 (air conditioning unit mounting section)
17 to 19
M10
1.25
40 to 54
M10
1.5
37 to 51
M8
1.25
24 to 36
M10
1.25
56 to 76
M10
1.5
53 to 72
8 mm
1.5
12 to 15
1/2 inch
1.5
20 to 25
5/8 inch
1.5
30 to 35
NOTE: About oil capacity for compressors SD7H13WM7359 X1 Series compressors are filled with 135 cc of oil (SP-10). Low oil level may cause it to seize up at high speeds and reduce durability while excessive oil may reduce its cooling performance. While the air conditioning is running, the oil is distributed in the refrigerating circuits. Therefore, the oil level must be adjusted following the instructions in table 1 when cha nging parts.
Lep SM4609007-0EN
Issued 09-07
Copyright © 9007-4
AIR CONDITIONER Description 2
1
3
4 5
7
6
3
8
10 11 7 9
5
CRPH06B065H01
1 2 3 4 5 6
BLOWER MOTOR RELAY CONTROLLER INSIDE AIR FILTER INSIDE/OUTSIDE AIR SWITCH-OVER MOTOR ACTUATOR BLOWER CASE AIR MIX MOTOR ACTUATOR
Lep SM4609007-0EN
7 8 9 10 11
HEATER CORE MODE SWITCH-OVER MOTOR ACTUATOR SCREW INTAKE CASE SCREW
Issued 09-07
Copyright © 9005-5
Disassembly and assembly
STEP 5
IMPORTANT: Service work on air-conditioning circuits must be carried out by approved service engineers.
1 2
NOTE: Never attempt to service the air conditioning system unless you are completely familiar with air conditioning and the safety precautions which must be followed when handling liquid refrigerant. Liquid refrigerant can cause severe and painful frostbite. Contact your dealer, who is experienced in servicing and handling of refrigerants. NOTE: When fastening the piping connection for refrigerating circuits, apply special oil (SP-10) to Orings and fasten the connecting parts using tightening torque specified in Table 2, page 3. Further, tighten screws and bolts using torque specified in Table 3, page 3.
STEP 1 Remove the inside air filter (3), and remove the 4 screws (3) (5 x 14) to remove the intake case (10) (see page 4).
4
3 CRPH06B067A01
Drain the cooling water, detach the heat hose and then remove the 2 screws (4) (5 x 16). Remove the pipe clamp (2) and the AHC bracket (3), and then pull out the heat core (1).
STEP 6 1
STEP 2 Remove the blower case (5) by removing the 3 screws (11) (5 x 14) that mount the blower case to the unit case (see page 4).
STEP 3 1
2
2 CRPH06B068A01
3 5
6
Remove the rod D (1) from the rod holder (2) mounted on the lever of the mode motor actuator.
4 CRPH06B066A01
After removing the cooling hose (5), remove the 3 bolts (4) (5 x 16) fitted under the blower case (1) and pull out the blower motor (2). NOTE: Do not remove the fan from the blower motor.
STEP 4 Remove the 2 screws (6) (4 x 14) under the blower case (1) and pull out the blower controller (3). NOTE: Do not disassemble the blower controller.
Lep SM4609007-0EN
Issued 09-07
Copyright © 9007-6
STEP 7
STEP 9
1
3
A
2
32 B
3 5 4 4
1
CRPH06B069A01
Remove the motor actuator mounted on the lower unit case (5) and the upper unit case (1) by removing 3 screws. Remove the 11 mounting screws (5 x 16) from the lower unit case (5) and the upper unit case (1). Pull upward the upper unit case (1). WARNING: Paying attention not to have evaporation sensor cords caught by the case.
5
STEP 8
CRPH06B071B01
Installing the evaporation sensor:
2
NOTE: Attach the evaporation sensor to the holder, place the tip of the holder and sensor in place as shown in the figure above.
7 3 6
4
(1) Insert sensor holder into 13th and 14th columns. (2) Insert sensor holder into 5th and 6th columns. (3) 3RD column. (4) Ensure no unnecessary looseness. (5) Do not allow tip of the thermistor to extrude from tube to the left.
CRPH06B070A01
Pull out the evaporator (2) with its heat insulating material attached from the lower unit case. Pull out the evaporation sensor (4) with its sensor holder attached from the evaporator. Remove the 2 hexagon bolts (6) (M5x40) from the evaporator, and then, remove the expansion valve (3) from evaporator. Install O-rings (7) (5/8 and 1/2 NFO rings) onto a new evaporator and then fit the expansion valve. NOTE: Special care should be taken while installing to avoid O-ring engagement. Do not reuse O-rings. Install O-rings with bare hands.
Lep SM4609007-0EN
Issued 09-07
Copyright © 9005-7
STEP 10
STEP 12 Replacement of the inside/outside air switch-over motor actuator:
c
F
CRPH06B072A01
Remove the rod clamp (C) interlocking the mode motor actuator and mode cam by pushing to the direction of ARROW. Remove 3 mounting screws from the motor actuator and remove the motor actuator with its rod clamp and lever attached from the unit. Remove the rod clamp and lever. Then, install them on a new motor actuator in the reverse order of the disassembly.
E CRPH06B074A01
Remove the screw fixing the motor actuator with its lever (E) attached, and remove the motor actuator. Remove the lever from the motor actuator. Install a new motor actuator in the reverse order of the disassembly.
STEP 11 Replacement of the air mix motor actuator: B A
CRPH06B073A01
Remove the rod (B) from the lever by pushing the rod clamp (A), which is attached on the lever of the motor actuator, to the direction of ARROW. Remove the 3 mounting screws from the motor actuator, and remove the motor actuator with its rod clamp and lever attached from the unit. Remove the rod clamp and lever from the motor actuator. Install a new motor actuator in the reverse order of the disassembly.
Lep SM4609007-0EN
Issued 09-07
Copyright © 9007-8
NOTES .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... .......................................................................................................................................................................................... Lep SM4609007-0EN
Issued 09-07
Copyright ©
27
K1
K2 MA
D
REG
D1
ITEM
D
VB
VA
25
26
B45
* 30
P
MB
29 *
29 *
REG
22
28
*
83
P2 VB
AU
Dr
L1
T1
B1
VA
L2
P3
P2
P2
B2
P3
T1
T1
Pil
T2
MB
P
P
MA
Pil P1
21
15
23
21
23
Pil T2
T2
Pa9
J
GA
I
P1
GB
MU
A
B
A=
MAIN RELIEF (STANDARD)
31.4 MPa / 314 Bar / 4554 PSI
A=
MAIN RELIEF (BOOST)
34.3 MPa / 343 Bar / 4974 PSI
B=
BOOM RAISING PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
B1/B2 =
RELIEF ON BOOM HBCV
39.2 MPa / 392 Bar / 5685 PSI
C=
BOOM LOWERING PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
D=
DIPPER OUT PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
D1 =
RELIEF ON DIPPER HBCV
39.2 MPa / 392 Bar /5685 PSI
E=
DIPPER IN PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
F=
BUCKET OPEN PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
G=
BUCKET CLOSE PORT SECONDARY RELIEF
36.3 MPa / 363 Bar / 5264 PSI
H=
PILOT PRESSURE RELIEF
3.9 MPa / 39 Bar / 565 PSI
I=
RIGHT-HAND SWING PORT SECONDARY RELIEF
29.3 MPa / 293 Bar / 4250 PSI
J=
LEFT-HAND SWING PORT SECONDARY RELIEF
29.3 MPa / 293 Bar / 4250 PSI
K1/K2 =
TRAVEL FORWARD PORT SECONDARY RELIEF
35.8 ±7.8 MPa / 358 Bar / 5511 PSI
L1/L2 =
TRAVEL REVERSE PORT SECONDARY RELIEF
xxx MPa / xxx Bar / xxx PSI
N1/N2 =
NEGATIVE CONTROL RELIEF
3.38 MPa / 33.8 Bar / 490.2 PSI
Q=
RELIEF VALVE BLOCK COUNTERWEIGHT
27.5 MPa / 275 Bar / 3988 PSI
W1/W2 =
CRUSHER OPTION SECONDARY RELIEF VALVE
xxx MPa / xxx Bar / xxx PSI
Z=
MAIN RELIEF VALVE FAN
25 MPa / 250 Bar / 2626 PSI
51 =
ACCUMULATOR PRECHARGE
1.5 MPa / 15 Bar / 212 PSI
Dr
P
A
ITEM
15
B
Pb7-2
LEFT FORWARD LEFT REVERSE
RIGHT FORWARD RIGHT REVERSE
1.8 0.18 MPa 1,8 bar 26 psi T1
42 PS1
A
T6
Pc5 T2
T4
T5
Ps2
15
T
T
D
Y9 A
E
B5
OUT
ARM (1)
A9
ARM (2)
Pa5-2
B
Pa9
IN
1
Pb5
A
Pa5-1
15
43
F
IN
ON
G
Pa9
OPEN
BUCKET
PC4
D8
T
83
B4
A
10µ D7
150 MESH
76
15
*
90 OPTION
A4
DR2'
79
D6
*91
Pb4
B1 D3
79
5
4
1
6
C
85
T
15
T1
42 43 D1
52
B7 DOWN Pb7-1
BOOM (2)
Pb3
Pa7-2
D7
A
BOOM (1)
52
UP
Pa3
Pb7-2
29
Pa7-1
Pil
Pa7-2
15
B6
Pa3
B
T 1.5 MPa 212 psi 15 bar
Y4
LEFT
Pb2
2.5
Pa2
RIGHT 2.5
Y2
P3
*W1
SWING
*
P
55
W2
Pb6
BACKWARD
4
Pa6
C3
0.02 MPa 2.9 psi 0.2 bar
C2
55 3
Y5
10 µ
P0
Y3
TRAVEL
55 42
T
2
T
A
Pb1
10µ
55
86
Y1
Y6
HYDRAULIC RESERVOIR BREATHER BY-PASS VALVE SCREEN FILTER RETURN FILTER MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR SWING MOTOR TRAVEL MOTOR BRAKE RIGHT BOOM CYLINDER LEFT BOOM CYLINDER DIPPER CYLINDER BUCKET CYLINDER BOOM SAFETY VALVE (OPTIONAL) DIPPER SAFETY VALVE (OPTIONAL) DIPPER LOAD HOLDING VALVE BOOM LOAD HOLDING VALVE FILTER (ULTRA-CLEAN) OIL COOLER RETURN MANIFOLD ACCUMULATOR 6 SOLENOID VALVE BANK BOOM & BUCKET CONTROL LEVER SWING & DIPPER CONTROL LEVER TRAVEL CONTROL PEDAL BOOM & DIPPER CONTROL SHOCK ABSORBER PILOT AND RETURN SYSTEM MANIFOLD FILTER PILOT SYSTEM MANIFOLD SECOND OPTION CONTROL VALVE CONTROL PEDAL (OPTIONAL) SECOND OPTION CONTROL VALVE 3-WAY SELECTOR (OPTIONAL) RETURN FILTER (OPTIONAL) CONTROL SHUTTLE BLOCK (OPTIONAL) SWING SHUTTLE BLOCK PILOT CIRCUIT FILTER SHUT-OFF VALVE (OPTIONAL) HAND/FOOT CONTROL PILOT FILTER PILOT FILTER BY-PASS VALVE HYDRAULIC BREAKER VERSION PLUG SAFETY VALVE VERSION PLUG HYDRAULIC PUMP FOR COOLING HYDRAULIC CIRCUIT COOLING HYDRAULIC MOTOR SWING PILOT PRESSURE SWITCH BREAKER / CRUSHER PILOT PRESSURE SWITCH SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH BREAKER PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SWITCH (YELLOW BAND) TRAVEL PILOT PRESSURE SWITCH SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH PUMP PRESSURE SENSOR (P1) PRESSURE SENSOR (NEGA-CONT) PUMP PRESSURE SENSOR (P2) (BLUE BAND) OVERLOAD INDICATOR PRESSURE SWITCH PRESSURE TEST POINT SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND) PILOT PRESSURE SOLENOID VALVE (BLUE BAND) SWING BRAKE SOLENOID VALVE (PINK BAND) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) POWER-UP SOLENIOD VALVE (YELLOW BAND) CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND) MAIN PUMP PROPORTIONAL SOLENOID CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE COOLING HYDRAULIC MOTOR SOLENOID VALVE PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC MOTOR
Pa1
1
* 76 B42
1
15
P1
A4
3
2.0 MPa 20 bar 290 psi OFF 1.4 MPa 14 bar 203 psi
*
P2
P3
PH
PP PA
PT ON
B27
A
Pr2
A
Pr1 2
83
B44
BACKWARD
P2
C4
C5
FORWARD
P
0.103 MPa 14.5 psi 1 bar
P1
B1 A1
82
60
FORWARD A6
B2
* 78
51
C1
TRAVEL A2
Pb1
PC2
Pa4
A3 B3
T
43
DR2'
32
P
Pa1
P5
A7
B2
D2 D1
B
58
*
DR2
3
2
T
T4
A8
CLOSE
R
58
Pa8
D9
P
B8
Pa5-2
Pb8
0.127 MPa 18.4 psi 1.27 bar
* B24
* B28
15
57
Pb9
OUT 0.004 MPa 0.58 psi 0,04 bar
30
B9
A5
0.07 MPa 10.15 psi 0.7 bar
P
Pil
2
10µ
N1
31
Pc1
A1
SECOND OPTION
71
N2 Pa10
121
B1
*
DR1
73
73
O
*91
DR1'
41
T3
0.3 MPa 3 bar 43.5 psi
DESCRIPTION
CX460 EXCAVATOR HYDRAULIC SCHEMATIC
1. 2. 4. 5. 6. 10. 15. 16. 21. 22. 23. 25. 26. 27. 28. 29. 30. 31. 32. 41. 42. 43. 51. 52. 53. 54. 55. 57. 58. 59. 60. 71. 72. 73. 76. 78. 79. 81. 82. 83. 85. 86. 90. 91. 120. 121. B22. B23. B24. B25. B26. B27. B28. B42. B43. B44. B45. M3. Y1. Y2. Y3. Y4. Y5. Y6. Y7. Y9. Y31. Y32.
RIGHT LEFT
PRESSURE SETTINGS
C
D
16
P1
DESCRIPTION
ON
B26
1.2 MPa 12 bar 174 psi OFF 0.8 MPa 8 bar 116 psi
15 B4
71
71
P
T
B43 LEGEND P1 PUMP
P4
P5
T4
T5
72 58
P3
P2
P1
T3
T2
55
*
1
T1
2S 3S
FORWARD
1S
S2 S3
S1
DOWN
*B25
4
85
SWING LEFT RIGHT 3 1
BOOM DOWN
BUCKET OPEN CLOSE
UP 3
2
R T 1
3
B
4
85
D
C
B22
59
ON 0.5 MPa
OUT
OFF 0.3 MPa
72.6 psi 5 bar 43.5 psi 3 bar
* 85 *
B23
A1
S1
A2
174 psi B1 12 bar
A
* 79
Pi2
41
T 2
3
T
4
15
15
116 psi 8 bar
Pb4 5a4
Pa4 P
85
T
15
Pb9
Pa1
Pb1
Pa6
Pb6
*
P
Pa10
182 cm3
Dr
ISUZU 6UZ1X
15 Pb1
CONNECTION ITEM NO
270.0 Kw 1950 tr/mn
*
a3 A4
Tc
15 A
182 cm3
40.2 cm3
M 15
COMPONENT ITEM NO. COMPONENT NUMBER
40 cm3
P
15
S
PIPING CROSS-OVER Pi1
15
57
PIPING CONNECTION
42
B2
S2
OFF 0.8 MPa
IN
Y31
1
ON 1.2 MPa
Y9
COMPONENT BOUNDARY HOSE
P
15 A
(REAR)
(FRONT)
2
T
F
2
LEAK-OFF-RETURN
FORWARD
T H
OUT
RETURN TO RESERVOIR
10
PILOT SYSTEM CIRCUIT 1
IN
BACKWARD
A2
G
T
ARM
BACKWARD
A3
UP
53
85
TRAVEL (RIGHT)
TRAVEL (LEFT)
85 P
P
PILOT SYSTEM PUMP
Y7
E
81 54
P2 PUMP
OPTION
121 Y32
43 T
Z
H 15 cm3
120 B4
OPTION ITEM NO
A3 15 cm3 B3
M3
CX460 EXCAVATOR HYDRAULIC SCHEMATIC Number 87574463A
Copyright ©
FUSE C (20A)
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS) 65A
YG 451
9
YL 451
3
0.85LgR 0.85GB
4
MOTOR-ACT (AIR-CHG.)
2 3 5 4
1
CN.33 0.85LR 901
2 3 5 4
CN.34
BrG 461
8
G 464
0.85GL 413
9
0.85GL 413
0.85OL 415
10
0.85OL 415
0.85BO 425
11
0.85BO 425
VY 434
12
OR 455
13
PW 255
15
1.25O 895
WR 501
16
WR 501
0.85LgR 502
17
0.85LgR 502
GrR 504
18
GrR 504
BrR 506
19
BrR 506
YR 552
20
YR 552
0.85P 580
21
P 580
0.85PL 581
22
PL 581
4
0.85BL 661
1.25BY 945
2
1.25RW 559
1
R
1.25B 776
2
Y
2
S19
3
G 854
1
RG 855
2
R 852
758,759
2BG 600
S20
3
RB 856
1
RW 857
2
R 853
RG 855 R 853
G 854 CTWT REMOVAL MAIN SW
1
R 852
1
2
O 455
2
P 255
3
S18
6
RY 858
Br 556
6
B 773
OR 455
7
O 455
PW 255
8
P 255
1
1
1P-M CN.T1
1 1P-F CN.T2 VR 917
2
5 0.85BrR 916
1
B 751
OW 546
4 L 913
3
3
SENSOR
CYLINDER #1
M14 M15 M20 P1 P2 P3 P4 P5 P6 R1 R3 R4 R5 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S18 S19
CYLINDER #6
S20
B47
B21
t °C
0.75Y 485
1
0.75YG(FT)
0.75P 864
2
0.75RW(PCV1)
0.75W 866
3
0.75RB(PCV2)
5
BG 656
G 464 G 465
B3
SUPPLY PUMP
0.75RL(PCV1)
VALVE (PCV1)
Y33
SUPPLY PUMP VALVE (PCV2)
1.25RG 850
1
1.25W(INJECTOR POWER1)
1.25RW 851
2
1.25R(INJECTOR POWER2)
Y34
0.75GW 854
5
0.75L (INJECTOR ORDER1)
0.75WL 857
6
0.75LR(INJECTOR ORDER4)
0.75GB 855
7
0.75LY(INJECTOR ORDER2)
0.75G 856
8
0.75LW(INJECTOR ORDER3)
0.75WB 858 0.75WR 859
9
0.75GR(INJECTOR ORDER5)
10
0.75GB(INJECTOR ORDER6)
S21 S25 S51
CYLINDER #5
CYLINDER #3
S52 CYLINDER #2
CYLINDER #4
AIR INTAKE TEMP. SENSOR
0.85BO 492
1
0.75OL 482
2
t °C
B6
BARO SENSOR 0.85Y 476
1
0.85YL 486
3
0.85BY 496
2
S53 S54 S55 S61 S62 S63 S64 U1 W1 X2 X3 X4 X5 X6
B48 X7 X8 X9 X15 X23 X24 Y1 Y2
AIR CLEANER SENSOR
0.85L 418
1
Y3
0.85BL 661
2
S62
Y4 Y5
0.85BO 425
1
0.85OL 415
2
t °C
B2
Y12
CTWT LOWER
Y13
(GREEN TAPE)
ARM TOP
RB 856
Y14
F21 F22 F23 F24 F25 F27
ARM
B 775
BOTTOM
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20
(BLEUE TAPE)
1.25RG 850 121
OP-COM1
0.75GB 855
0.75GW 854 119
120
OS-INJECTION2
OS-INJECTION1
0.75WL 857 118
1.25RW 851
0.75G 856 117
116
OP-COM2
OS-INJECTION3 OS-INJECTION4
0.75WR 859 115
OS-INJECTION6
0.75WB 858 114
OS-INJECTION5
OS-PCV1
113
0.75P 865
0.75WB 870 112
111
RAISE
B 774
0.85RY 834
OM-EGR MOTOR1 U
BOOST PRESS.
B45
(YELLOW TAPE)
RW 857
0.75YB 872
t° C
PRESS. SENSOR (HBCV)
CTWT
B 772
5
110
5
2 B 750
Y31
0.75R 954
OM-EGR MOTOR3 W
B51
Y6
4
0.75BR 497
SENSOR
HYD.OIL TEMP SENSOR
RY 858 BG 670
109
1
S55
Br 556
SG-5VRT4(BOOST P)
2LR 915
1 VR 912
330,546 0.85B 756
1
BG 670
0.85BW 689
2
010,543
540,541
3LR 060
B 759
2BG 600
2B 700
Y32
0.85BG 641 0.85GrR 437
5
108
5WR 003
8R 203
1
630,652,660,661
0.85BG 630
2B 758 1
4
SG-SLD4(CRANK)
2
1
2 3
B 775
1.25YG 944
Br 556
0.75L 951
0.75BY(GND)
RESERVE TANK LSW.
HYDRAULIC MOTOR (FAN)
BG 670
107
0.85BL 422
1
0.75G 955 0.75L 953
IF-CRANK+
11
BOOST TEMP.
M12
B43
3
B 772
0.75G 950
0.75P 864
3
0.85BG 427
3
106
105
OS-PCV1
2
0.85L 412
3
B 772
IF-CRANK-
0.75GB 871 104
102
103
OM-EGR MOTOR2 V
0.85BL 687 99
100
SG-SLD5
0.75L 953 98
IF-G(REM) ANGLE
0.75G 491 101
90
IA-COMMON.R PRESS
82
87
SP-5V5(COM.R&EGR)
IA-COMMON.R PRESS
94
93
IS-EGR PSTN2 V
IS-EGR PSTN1 U
91
92
IS-EGR PSTN3 W
IA-BOOST PRESS
97
OS-PCV2
96
95
89
OS-PCV2 SP-5V4(BOOST P)
88
86
85
84
IA-WATER TEMP
83
IA-FUEL LEAK.TEMP
79
80
SP-5V3(OIL P)
SG-5VRT3(OIL P)
78
77
76
75
74
IA-BOOST TEMP
73
72
IA-INTAKE TEMP
70
71
IA-BARO
69
68
66
67
IA-OIL PRESS
65
64
IA-ACCEL PSTN2
61
63
IA-ACCEL PSTN1
SP-5V2(BARO)
59
60
SG-5VRT2(BARO)
58
57
56
55
54
53
52
IS-DIAG
51
50
49
47
48
IS-MODE MAP2
IS-ENG STOP SW
45
46
IS-IGKEY(START)
44
42
SP-5V1(ACCEL)
40
39
41
SG-5VRT1(ACCEL)
OS-MAIN RELAY
38
CC-KW2000
34
IS-MODE MAP1
IS-MEMORY CLEAR
32
31
29
30
IS-IDLE UP SW IS-IDLE DOWN SW
IS-IDLE MANU SW
25
IS-MODE MAP0
21
24
IS-IGKEY(ON)
OS-MAIN RELAY
20
SG-SLD1
19
IF-SPD
18
37
CC-CAN-L
CC-CAN-H
14
17
OS-OIL P. LAMP
11
OS-GLOW LAMP
OS-STARTER RELAY
10
OS-GLOW RELAY
8
OF-TACHO
7
6
OS-DIAG LAMP
OS-BOOST LAMP
5
PS-+B
81
2
PS-+B
PG-CASE(GND)
62
PG-SIGNAL(GND)
4
43
PG-SIGNAL(GND)
PG-POWER(GND)
3
PG-POWER(GND)
36
35
33
28
27
26
23
22
16
15
1
PG-POWER(GND)
A2
13
9
ENGINE CONTROLLER
12
CN. A0
SG-5VRT5(COMMO.R)
0.75W 481
0.75W 479
0.75R 471
0.75WG 873
0.75G 874
0.75YG 875
0.75GR 487
0.75W 867
0.75RG 477
0.75W 866
0.75WR 484
0.75Y 485
0.75RY 478
0.75BY 498
0.75WL 483
0.75OL 482
0.85YL 486
0.75YB 488
BL 956
BL 957
0.85Y 476
0.85BY 496
PB 589
WR 501
GrR 504
BL 956
YR 553
PG 588
0.85BrY 575
0.85LgR 502
YR 552
PL 581
P 580
BrR 506
1.25GR 395
1.25GR 394
0.85BG 632
0.85BG 631
0.85BG 630
1.25B 732
1.25B 731
1.25B 730
117 118
0.85LY 402
0.85BG 427
1 2
1 2
0.75BY 498
(NEGA_CON-1:FRONT PUMP)
2
58X
90 91 92 93 94 95 96 97 82 83 84 85 86 87 88 89 114 115 116
98 99 100 101 102 103 104 105
0.75WB(5V) 0.75LY(OP-SIG)
PRESS. SENSOR
0.85WG 417
1 2 3 4 5 6
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
3
(BLUE TAPE)
0.85LY 407
SWP
106 107 108 109 110 111 112 113 119 120 121
1
B44
2
AMP HYBRID I/O 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
BG 652
2B 748
RW 558
531,532,567 890,900,901
CN. A1
3
0.85BY 421
1
OR 455
14
2
0.85PL 417
SWP
7
G 464
0.85Y 401 0.85YL 411
0.85LY 407
1 2 3
BrG 461
10
PRESS. SENSOR (P2)
2
SDL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
4
3 GR 982
1
2 B 725
WR 555
5 BrW 260
4
3
2 B 728
GrR 893
1 PW 819
CN.23 CN.32
1
630,641,650,651,652,654,660,,661,670,681
R 225
1.25BG 600
1.25GR 394
BG 636
5 LR 250
4
2
1
3 2LR 060
BrR 506
2
AMP 040 MULTI LOCK
4 5
1
2
1
2
60B 799 0.75GR 396
1.25B 730
1 5
1.25B 701
B 702
710,711 713,715,725
B 722 4
3
2
5
1 YR 552
2LR 310
WR 541
GrR 504
1.25GR 394 2 3 5 4
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
CN. A0
58M
2 3 4 6 7 8
CN.21
1.25BG 600
B 702
1.25B 701
M
CN.9
1.25B 700
603,604 603,604,636 WR 541
2LR 310
0.85GrR 010
394,540
LgR 542
WR 391
1
461,501 502,504 506,552 895
2
0.85LR
LgR 503
0.85LgR 502
12
CN. 28 AMP NEW SCCS
0.85RY
1
BY 943
0.85GrG 437
B28
1 2
633,634,635,637
1
YG 942
0.85L 418 LY 435
0.75YB 488
B42
1
58X
1.25BG 600
M5
5
CN. 51
AMP 070 MULTI LOCK
11
18 0.85Y
BrY 432
4 6
1
0.85GL 413
1 2
255,256,413,415,425,501,589
WR 555
2
13
5
3
L 418
PW 255 1.25V 256
10
MOTOR-ACT (MODE)
BrY 432
0.75GR 396
0.85YG
YG 431
1.25BG 600
4
1.25B 701
LG 430
2
5
3
413,415,418,425,430,431,432,435,437,461,464,895
1
LY 435
0.75RL(GND)
9
12
0.85BG 660
400,410,411,412,417,420
YG 431
GrG 437
1
2B 700
630,670
LG 430
4
3
0.85YW 270
1
3
0.85LW 0.85LgB
8
0.85GR 896
2
(GND) 2B
K11
2
0.85Br
(COMP.POWER) 0.85WG
K10
K3
1
1
1.25LW 340
(MAIN POWER) 2WG
WR 535
0.85YB
9
0.85BR
0.85OR 386
5
0.85GR 567
5
27
3
(ILLUMINATION) 0.85RB
0.85OR 385
0.85GB
WR 980
4
14
GY 566
17
0.85GR 567
23
14
(RECIEVER DRYER) 0.85GW
3
0.85LgR
(WATER TEMP.SIG) 0.85BrW
2
0.85Y
WR 531 0.85GR 890
0.85YB
1
1
9
11
5
28
0.85LR
VR 524
LAMP(CAB)
LAMP (HOUSE,BOOM)
0.85VR 371
0.85RY
0.85YL
15
HORN
0.85VR 370
0.85LgW
4
VW 525
4
3
YR 560
3
0.85YR
7 16
0.85VR 900
10
0.85B (LIMIT SW.DOOR) 0.85O (LIMIT SW.WINDOW) 0.85YW
2
8
B 725
5
0.85YG
050,250,260,819
BY 561
LW 532
8
LgR 503
24
2WR 050
0.85GW
PL 562
6
1
13
5
0.85W
0.85GW 291
12
0.85G
0.85GW 290
0.85LW
060,503,893,982
WR 555
0.85GW
PW 563
4
290,370,385,896
12
CN. 12
29
SDL
0.85Br
1 2
7
0.85WL
5
1 2 3 4 5 6 7 8
CN. S0
9
0.85R
CN.36
BG 657
CN-A
CN.53
1 2 3 4
1 0.85GrR 010
6
3 WR 390
1.25LgR 540
5
2
4 1.25RW 220
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1
2 0.85LY
CN. S9 CN. S7
1 2 3 4 M
CN. S4
0.85YL
0.85WG
2 3 5 4
BG 657
2BG 600
58X
418,430,431,432,434,435,437,455,464,580,581
11
CN.37
1
FUEL SENSOR
300,464,630,670,810,840,841,842,980,982
SWP
CN. 4
25
CN.31
2 3 5 4
0.85B 754
1 2 3 4 5 6 7 8
MEMORY 2Mbyte
0.85LgW
SUNLOAD SENSOR
1
0.85B 753
0.85B 754
CN.U6
FLASH
6
BW 565
2 3 5 4
17
0.75RY 478
3
1 2
RAM 2kbyte
13
WL 564
2
1
0.85B 753
R5
58X
I/O
0.85WL
0.85LgB
MOTOR-ACT (AIR-MIX)
M6
0.85WR
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
BrG 441
0.85RG
0.85WR
4
0.85BR
G 450
64
1
3
30
0.85BR
63
TRAVEL MODE
0.85YR
15
0.85RG
0.85BrR
0.85WG
ONE-TOUCH IDLE
5
0.85B
2
0.85WG
LG 430
2WG
16
26
0.85BR
62
M
UPPER PILOT
2
2
M
BrY 432
CN. S5
61
CN. S6
SWING PILOT
12 3 4 5
60
1 2 3 4 5
SPARE23(SW.)
M7
1 2 3 4 5
WG 448
0.85WG
22
B61
0.75BR 497
t° C
B24
1 2
59
0.85BrR
3
0.85W
K6
2
0.85BW 420
AMP
WARNING CHG.
4
0.85G
18
20
K5
G 465
0.85WL 410
CN.D3
YL 451
K17
CN. S8
2R
17
21
19
B 775
0.85B 744
K2
0.75RW(5V) 0.75L(BP-SIG)
0.75GR 396
1 2
58
0.85OB
2
1
0.85GY
1 2 3 1 2
17
0.85R
BW 565 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
3
0.85OB
1.25BG 600 P 592
PL 593
0.85O
15
14
16
1 2 3
16
BW 565
TO BEACON
B 775
58X
HYD.FAN REVERSE
0.85B 741
5
8
0.75GR 487
B1
1 2
GrG 437
BG 603
WL 564
1
2
SWP
VY 440
57
18
PW 563
BG 656
0.85WY 400
CN.T9
56
COOLANT
BG 603
13
0.75RG 477
2ND-OPTION LINE PILOT PRESS.
1 2
WORK MODE
7
X2
B 755
CN.H2
LY 435
0.85B 740
GrR 893
1 2 3 4
OG 442
55
B 711
58X
54
17
12
B22
1
SENSOR
11
Y7
CONT.
B 734
CN.H0
AUTO MODE BREAKER PILOT
0.85GR 231
B 711
2
SWP
OR 455
15
4
0.85BY 941
CN.B8
VG 447
53
0.85BL 490
YR 552
2
WATER TEMP. 0.75BR(BT)
K11 K17 K30 K31 K32 K33 M1 M3 M4 M5 M6 M7 M8 M9
B50
VCC
4
PUMP
1 2
52
8
1
DEUTSCH
BEACON L/M MODE
0.85BL 490 0.85GR 231
0.85YR 940
CN.H1
L 418 YG 431
0.85LG 480
WL 564
BG 656
2
SUMITOMO HW090
0.85RB
1
51
0.85LY 470
PW 563
1
LAMP (BOOM) 2
7
6
BG 656
E2
24V 70W
6
3
G 464
CN.R0
2R
2
0.85L 480
PL 562
2
SWP
6
1
1
0.85B 744
0.85LY 470
11
G 464
1 2 3
0.85BrW
0.85BrR 897
VR 841
10
BG 656
LAMP (BOOM) 1
16
2LR 310
BrY 432 BG 652
VR 841
PL 562
1
CN.R1
2L
BLOWER-OFF RELAY
CN. 4
5
2
2
G 450
2
BG 656
G 464
B27
1 2
M8
M
0.85YW
0.85B 740
5
1
1
SWP
BLOWER MOTOR
30
2
4
CONDENSER FAN
0.75BW
1 2 3
0.85PL 581
0.85L
0.85B 744
BEACON
Y(VCC)
6
1 2
39
20
603,636
GLOW
19
BL 686
GND
T
1 2 3 4 5 6 7 8 9 10 11 12
CAN L
19
3
E2
24V 70W
G 450
BY 561
B25
CN.A8
0.85P 580
14
2L
2
1
0.85GrR 010
YR 560
0.75R 954
OB(GND)
15
AMP
29
2B
3
0.85BrR 890
1
4
9
BG 651
CN.B3
40
CAN H
1
0.85BrR 890
0.85GrR 010
BY 561
5
G(MRE) SENSOR
4
PRESS. SENSOR (P1)
1.25LgR 540
YR 560
18
0.75L 953
SWING PILOT PRESS.
3
8
0.75B
0.75G 955
0.75WL 483
PACKARD CN.A7
BLOWER AMP
NO USE
1
0.85LB
CN. S1
48
0.85LB
2
3
0.75RB(WT)
1 2 3
A6
P6
VW
BW 688
1 2
OW 458 OG 459
18
Y
2
7
BREAKER PILOT PRESS.
1 2
46
0.85OB
2
G 464
3
SPARE19(SW.)
3
(RED TAPE)
2
CONTROL PANEL
YG 431
2
3
LY 444
4
0.85GY
E1
24V 70W
WR 390
10 0.85LY
TRAVEL PILOT PRESS.
G 464
CN.D2
45
CN. S2
B26
SUMITOMO HW090
SWING LOCK
CN. S3
1
CN.D1
WG 446
2
BG 650
SUMITOMO HW090
BrR 530
44
2
0.85B 740
BG 636
LG 430
CN.D0
43
1
0.85B 741
1.25LgR 540
A9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
ENG.STOP SOFT/HARD
1 2
0.85LgR 891
1
0.75L 951
K7 K8 K10
B23
2ND-OPTION LINE PILOT PRESS.
LAMP (HOUSE)
E3
0.75G 950
B49
+
6
SUMITOMO HW090
1 2
1
1 2
42
BG 655
090
CHECK
CONTROL AMP
7
BG 655
CN.B0
BrG 460
41
6
1 2
38
TEST
BG 655
HORN (LEFT) 24V,303Hz,115dB
B 754
LW(GND)
UPPER PILOT PRESS.
1 2
BREAKER MODE
2
24V 70W
0.75Br(COM-SIG)
14
TEMP. SENSOR
LY 435
HORN (RIGHT) 24V,333Hz 115dB
13
0.75G 491
FUEL LEAKAGE
LY 435
WR 390
B5
R4
1
BrG 461
CN-A
GrG 445
2
BG 655
5
TRAVEL ALARM 24V,107dB
CN.U7
37
LY 435
4
B81
0.85B 753
0.85BrR 897
CN.30
BG 655
LY 435
0.85LR 901
0.85BG 604
2 3 5 4
6
BrG 461
B81
K33
1
BG 655
G 464
1 2
HIGH DUMP
1.25RW 220
BG 655
3
0.85B 754
0.75W 481
BREAKER&CRUSHER PILOT PRESS.
2
0.85VR 900
L(5V)
Y9
(YELLOW TAPE)
SWP
YG 443
1
LY 435
G 464
CN-A
0.85BL 490
2
1
0.85BG 604
5
BrR 840
CN.F0
0.85L 480
B 713
11
LY 435
1
1 2 3 4
0.85LY 470
10
LY 435
2
0.85LR 901
12
SENSOR
B 767
H2
0.75R 471
0.75WR 484
SUMITOMO DL090 CN.A3
B 713
BrG 461
1
2
PRESS. SENSOR
OIL PRESS.
1.25OW 300
B 752
B 752
MAIN
0.85BG 604
G 464
1
W 820
58X
36
W 820
COMMONRAIL
60B 798
GrG 445
830,840,842
BrR 840
3 4
GW 810
M6
CN.D4
BZ. STOP
B 767
0.85B 760
0.85BrR 890
8
14
EVA-SENSOR
THERMISTOR (INNER TEMP.)
1 2 3 4 5 6
GrG 445
AIR CONDITIONER
E52
B 710
7
LW 532
1.25RW 220
G 464
2
2
G 464
G 464
B 772
CN.B2
1 2 SUMITOMO MT090 CN. 55
S21
32
35
CN.19
LW 532
WR 391
BrG 461
WG 448
WR 390
SDL
CN.61
SDL
2
1
B 716
0.85GR 231
1
3
2
0.85B
0.85L
1 2 3 4
1.25BG 600
0.85Y
VW 842
6
13
2ND OPT.PILOT
0.85B 742
BrR 840
BrR 840
2SPEED
1 2
5
12
34
1
OW 300
B 752
LAMP (CAB)2 0.85GR 892
1
090
VW 842 WG 448
B 711
33
24V 70W
1.25O 895
GW 810
2
1 2
BrG 460
VR 841
SPARE16(SW.)
RW 558
LAMP (CAB)1
VW
BrR 840
4
BOOM UP PILOT
BY 943
E3
4
BrG 460
3
VY 434
0.85YR 940
VR
4
BG 603
0.85VG 469
16
6
3
G 450
CN-A
YR 940
2
BrR 840
2
CN. 52
GrR 893
0.85B 743
BrG 460
1
3 2 1 SDL CN. 50
15
2
YR 830
18
CN. 3
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
ONE TOUCH IDLE
1 2 3 4 5 6
GrR 893
0.85B
VR 240
17
2
GR 982
1.25B
2
GND
1
WR 980
14
5
1
TA GND
B 717
13
GR 982
1
YR 830
ST
LR 251
WR 980
20
VCC
OPTION
1
BrR 840 1.25O 300
090
ACC ON
0.85LR 901
3
CN.M1
24
1 2 SWP CN. 54
12
0.85GR 894
VR 240
S16
OFF
0.85LR 901
2
VW 842
CN.M0
26
ST
HEAT
ST
BrG 461
1
VR 841
1 2
19
GND
M
0.85BrR 890
OW 301
SWP
SERIAL INPUT
PL 584
ACC
11
19
W
20
ELE.FUEL PUMP
CN.G2
PW 583
G2
0.85GR 890
RW 558
0.75RL(VCC)
M9
M
2
OW 300
1.25O 895 0.85B 771
1
Y8
1 2
WR 571
25
G1
Br 556
2
X7
1.25O 300
240,448
ACC B
VW 842
10
1
222,391,710,970,971,972,973
CONNECTION ON
9
Br 556
1.25B 778
M20
090
22
HEAT
X6
VW 842
1
CN.C6
PROTECT SERIAL OUTPUT
CAB SEAT
VR 841
BO 943
1
24V
1 2
LG 570
8
CN-A
SW. TO ACCESS
28
BrR 840
VR 841
CN.B5
20
OFF
BrR 840
7
GW
24V
KEY SWITCH
THROTTLE VOL.
SHUT OFF
1.25O 895
1 2
SG
PG 586 BP 587
7
CN-A
Rx
R3
GW 810
6
CN.Q2
P 585
21
5
OR 811
1 2
27
GW 810
GND
0.85GR
CN-A
Tx
12V OUT(BACKUP)
4
GR
2
B 714
S1
2
CN.Q0
23
3
S25
LIMIT SWITCH (GATE)
M
VW 842
4
YR 830
2
1 2 3
CN. 2
CN-A
5V
HORN SWITCH
VR 240
1
3
CN. 64
10V
58W CN.60
8
2
3
0.85BY 729
YG 942
0.75R 876
B53
V
1 2 3 4 5 6
BATT.CHARGE
BG 605
0.85RW 282
0.85BY 941
0.75GY(W)
B52
CN.A5
16
B 713
0.85BrW 804
18
0.75GW(V)
2
SUMITOMO DL090
LgR 542
SPARE12(CMP)
2
4
17
3
M14
1
1 2
7
1
1
BrW 804
090
3
GrG 445
12V OUT(MAIN)
2
CN.C5
0.85PL 417
BrR 543
1
B 777
1 2
0.85BL 490
LW 532
0.85LgW 803
SWP
5 12
1
BW 721
1
3
1
CN.C7
A GND
S15
1
2
2B 758
LgW 803
M3
WIPER MOTOR
OVER LOAD WARNING KEY SW.
S51
WV 931
1.25O 331
GND
BY 941
0.75G 874 0.75YG 875
4
TO LUBLICATOR
0.85YW 802
OW 894
GND U
G 464
GR
2
2
YG 942
0.75GB(U)
CONDENSER
BG 656
6
1
M
SWP
GW
1.25W 981
1
YW 802
U1
0.75LW(GND)
4
S52
1.25W 981
1 2 3
5
CN.P2
5
7
1
2
6
4
9
(YELLOW TAPE)
4
BrR 506
BG 606
3
8
3
1 2 3 4 5 6
BP 690
WIPER MOTOR(CCW)
0.85YR 281
2
MAGNET CLUTCH
435,461,464,895
VR
0.85RY 834
WR 980
300,840,841,842,980,982
8
SHUT OFF
0.85LW 801
603,604
STOP SIG.
12V
Y1
1
X15
SDL
CN-B
1 2
B 710
WR 391
R 222
LW 972
BL 973
CN.P6
PA YW 970
VW
5
5
1 2
BY 971
7
B 702
2
DUAL SWITCH
LW 801
ACCESSORY SOCKET
9
REV. SIG.
2
SWING
630,641,660,661,670
10
1.25B
24V IN (BACKUP)
1
B 757
GR 982
758,759
0.85BrR
WINDOW LIMIT SW.
RADIO AM/FM STEREO 24V,2A
S64
0.85YR 283
BW
1
2
GR 983
090
2
CN.P1
3
POWER (24V) IN
3 2 1 6 5 4 14 13 12 11 10 9 8 7
CN-B
1 2
CN.P5
WASHER CONT.(-)
0.85B 765
0.85B 771
CN.24
91A
CN.P7
WV
R 223
0.75B 877 0.75WG 873
SENSOR
CN.G1
BG 606
AMP MIC
PG 588
BP 634
B 734
1 2 3 4 5 6 7 8 9 10 11 12 13
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
SDL
CN.25
1 2 3
0.85BG 637
1.25BG 600 BrR 543
16
2
(LIGHT GREEN) 1
B61 B81 B82 E1 E2 E3 E4 E51 E52 G1 G2 H1 H2 K2 K3 K5 K6
EGR POSITION SENSOR
4 8 12 16 20
WASHER CONT.(+)
24V IN (MAIN)
0.75WL(W)
3 7 11 15 19
GrR
6
6
2 6 10 14 18
13
VW 280
0.75WB(V)
0.75YB 872
1 5 9 13 17
WASHER SW. IN
A4
ANTENNA
B 702
Y6
HARD
2
0.85BrW 804
M15
CRANK ANGLE (MPU)
0.85B 756
SOFT
1
2R 2B
CN.A2
YR
WINDOW CONTROL
3
0.75WR(U)
7
SUMITOMO DL040
LR
12
GND
B 702
8
0.75GB 871
1 2
11
WIPER SW.IN(CNT)
0.85LgW 803
M
24V
SWP
0.85LG 480
WIPER SW.IN(INT) LW
2
R 223
R 223
12V OUTPUT
WIPER CONTROLER
BL
VW 280
2
2
CN.G0
4
YW
1
1
2B 748
(YELLOW TAPE)
DC/DC(24V/12V) CONVERTER VW 280
RELIEF
2BG 600
YW
2
2B 700
8
2LR 915
2B 748
Y5
2B 700
BY
OW 546
2
2 STAGE
B 759
7
0.85B 763
GND (G2)
BY(SPK:R-)
1
(GREEN TAPE)
0.85B 771
LW
B 715
B752,772
6
0.85BrW 230
1 2
11
(BLUE TAPE)
LIGHTER 24V,5A
CN-A
0.85BW 420 0.85LY 470
BW 720
CN.Q1
2
5
E51
0.85YW 802
SDL
LW(SPK:L+) YW(SPK:R+)
W1
S14
HYD.FAN SW. 1
WV 930
3
2B 748
(RED TAPE)
0.85B 764
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BL
WIPER MOTOR(CW)
YG 451
4
OW 546
SWP
3
WV
0.75WB 870
B82
REFUEL PUMP
1 2 3 4 5 6
S13
BY 971
V
AUTO STOP ALARM
2GrR 330
CN.B1
2
10
U
0.85BrR 916
1
Y4
TRAVEL
1 2
0.85BG 604
BY
2
1 2
10
0.85L 412
9
YW 970
0.85B 761
2 STAGE
SWP
0.85YL 411
1
YW
1
B49 B50 B51 B52 B53
EGR MOTOR
S61
1 2 3
BG(B)
5
BY
2
L
X8
HBCV WARNING SWITCH
WG 448
B 725
0.85LW 801
CN.B6
9
3
6
1 2
P2 SIG
BrG 460
BL 973
CN.16
0.85WL 410
2
1 2 3
0.85WY 400
1
CN-A
3
S63
(RED TAPE)
CN. 65
A Vcc P1 SIG
BP 690
8
Y3
CONTROL
SWP
15
IMMOBILIZER
BL
1 2 3 4 5 6 7
14
SPARE11(A/D)
0.85BG 621
B 715
PA
FUEL SENSOR
0.85BO 425 0.85GL 413
X9
1
B 713
5
CN.S4
SWP
4
BL(SPK:L-)
(KWP2000)
OPT.SW (MULTI)
BrR 840
4
LW 972
CN.70
13
0.85BG 621
WR 390
7
SUMITOMO MT090
A GND
0.85VG 469
1 2 3
0.85OL 415
CN-A
6
CN. 63
THERMO SENSOR(O)
1 2 3
MEMORY CLEAR1
CN-A
CN. 62
0.85PG 598
1
LW
0.85BY 727
BG(B)
1
3
0.85BG 635
X23
VR 524 VR
OPT.SW (OPT.2SPEED)
2
WR
SDL
VW
3
CN.71
BP 690
B 711
CN.14
2
VR
R
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
8
1
3
JOINT CONNECTOR
3
2 1
PB 589
BrR 840
SDL
VW
BG(B)
1
7 BG 620
VW 525
2
CN.U8
RS232C
6
BG
CN.P4
VR
3
PB 590
X24
2
1
0.85B 762
58X
BG 633
VW
0.85VW 800
2GrR 330
SWING BRAKE
CN.T4
5
B 710
Y2
LEVER
1 2
PG 586
2
BW
2
1 2
4
0.85GR 896
2
L 913
R1
LOCK
(PINK TAPE)
SWP
P 585
11
TECH2 CONNECTOR
X4
MEMORY CLEAR2
1.25B 700
GW 329
0.85B 749
(BLUE TAPE)
SUMITOMO MT090 CN.U9
3
1
WR
1
1 2
2
VR 523
1 2 3 4 5 6 7 8 9 10 11 12 13 14
P5
LG 570
3
LIMIT SW. (F-WINDOW) WR
WR 571
VR
SDL CN. 10
RW 557
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
S54
13
YR 522
B 722
BG(B)
LR 521
WV 931
VW
1
12
YR
BW 721
2
VW
CN.P3
B
3
1 2 3 4 5 6 7 8
1
H1
1
LR
0.85GR
2
35
GrR 520
1
0.85B 760
B47 B48
5BW
1
1 2 3 4 5 6 7 8
BZ.
GY 566
14
1
SUMITOMO DL090
S53
0.85BG 604
BG 664
24V
VR 912
24V 0.85GR 831
M1
W
1 4 2 5 3
CN.B7
25
GrR
24V,10W
LIMIT SW. (DOOR)
HOURMETER
0.85BrR 360
1 4 2 5 3
AUTO/MANUAL SELECT SW.
1
A/C CONT.
5V 4.7k
6
M4
SWP
34
LCD
WR
2
0.85BrR
BG 603
0.85BG 645
2
CN.C8
INCR
GND
1
2BG 600
BG 636
BW 720
M
330,546
1.25BG 602
C
GLOW PLUG
1 2
33
WASHER
ROOM LAMP
E4
0.85B 745
1
SUMITOMO 090
DECR
WIPER
0.85B 745
WV 930
CN.B9
26
1.25BG
0.85B 704
WASHER
8R 100
CN.U5
ISC2
22
0.85B 704
3LR 060
010,540,541,543
1 2 3
24
BrW
SDL
ISC3
21
PUMP STOP
REFUEL PUMP
CN.S3
602,603,604,636,645,664
CN.15
36
1.25BG 602
M5
B42 B43 B44
M
B45
58X
BrW 804
SWITCHED DROP
20
2B 700
B
24V 7.0kw
1 2
31
23
1.25BG
1.25O 300
7
M10
K31
K30
BG 670
1 2
SWING SHUT-OFF
VARIABLE ISC
GND
6
1.25B 700
8
BG 651
58X
OR 811
WV 813
VR
1.25O 300 1.25BG 600
5Y 004
CN.T5
30
20
20
1.25GR 394
STARTER MOTOR
1 2
29
WL 812
WINDOW L/SW.
2GrR 330
5
B27 B28
M6
3LR 060
M8
(BLUE TAPE)
CN.E5
CUSHION
32
19
BrW 545
FPC
HIGH DUMP
SPARE1(PNP) SPARE2(PNP)
BrW
4
0.5mF
B
BG 650
CN.S1
S12
19
ALTERNATOR
GND
B 734
B 734
YR
P4
LgW 803
VR 523
2Gr 330
8R 100
60R 001
3LR 060
1.25GR 394
5Y 004
B25 B26
C
SUMITOMO MT090 CN.T6
LW 801
YR 522
18
E
1 2 3
28
17
VR
WIPER(CNT)
WORKING LAMP
BG 641
58X
2 STAGE TRAVEL
YR
R
1
1.25Br 030
CN.T8
VW 800
WIPER(CNT) WINDOW L/SW.
LR
2
B 759
B24
8R 100
CN.E4
RW 558
27
LR 521
1.25BrR 543
2
B 779
CN.E3
22
SWING BRAKE
GrR 520
16
18
ALTERNATOR
G1
CN.E1
HYD.FAN REVERSE
15
LR
S
1.25Br 030
R L
CN.A4
S11
WR 501
WIPER(INT)
ENG.STOP
S10
21
GrR
17 SWING LOCK
S9
YG 942
WASHER WIPER(INT)
16
12V
4
GrR
BZ STOP
1 CN-A CN.C0
2GrR 330
15
S7
12V
OW 546
WASHER
PANEL;SWITCH (R)
5V
17 18 19 20 21 22 23 24 25 26 27 28
1 2 3LR 060
CN.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SDL CN.22
1.25YR 208
3
ENG.STOP
CN. 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
2
2LR 060
1KΩ
CN. 2
BrR 544 1.25YR 208
BrR 530
V REF
CN. 1
BrW 545
WR 531
14
BrG 460
8kbyte
91-A
13
BrR
0.85BrY 575
E2PROM
Br 556
WR
ENG.STOP
W 820
TRAVEL PILOT
CN.13
WORKING LAMP
BrR
19
50
SDL
WR
14
3
1
5WR 003
B 0.85GrR 010
B 759
772,830
13
WARNING BUZZER
SPARE21(SW.)
OG 442
8
WR 541
GND (G1)
ENG.STOP
GW 810
49
OG
RELAY SAFETY
1.25G 020
M4
M8
WORKING LAMP
18
AIR CLEANER
BW 720
1.25BG 601
17
CAN GND
WV 930
18
1.25BG 600
BEACON
CAN
17
BW 720
1.25WR 209
REFUEL PUMP
I/O
WV 930
1
S8
47
0.85B 745
+
2B 700
1.25WR 209
OW 546
SPARE20(SW.) SPARE24(SW.)
0.85BW 420
LY 444
P3
31
16
12
YW 802
IMMOBILIZER OVER LOAD
0.85BW 420
LY
BO 943
1/4
0.85BG 645
-
2BG 600
SWING LOCK
GND
575,588,589,592,593
COUNTER
0.85PL 417
LY
8
TA INPUT
15
12
7
RXD
0.85PL 417
PL 584
633,634,635
SCI
14
0.85L 412
PW 583
2 STAGE RELIEF
TXD
0.85L 412
11
HYD.FAN MOTOR
RECIEVER
0.85YL 411
PL
15
SPARE13(CMP)
13
TXD
(BEACON)
B 734
RXD
0.85YL 411
PL
BP 587
SCI
12
0.85WL 410
11
HYD.FAN MOTOR
RS232C DRIVER &
0.85WL 410
TXD SWING LOCK
CN.6
TXD
0.85WY 400
YG 443
16
5V
0.85VR 900
11
9
5V
A/D 10 bit
10
10
NO USE
SIG THROTTLE VOL
0.85VR 900 0.85WY 400
PW
BY 941
A GND
0.85VW 800
YG
6
5V THROTTLE
9
RXD
PUMP RET
N1 SIG
VW 800
BZ STOP
1.25W 325
100Ω
OW 546
PW
24VB
1KΩ
W 820
8
YG
PROTECT
24V
7
9
YR 940
NO USE
W 820
10
14
PROTECT
0.85GR 831
RXD
S6
1 2 3 4 5 6 7 8
13
AUTO MODE
3 4 1 2 5 6 7 8 9
5
GND
OG
8
CN.11
GND
0.85GrR 010
6
CN.E2
PWM
11
5
GR 831
BZ STOP
PUMP OUT PWM
D/A 8 bit
3
GND
AUTO MODE
0.85GrR 010
CN.E0
SINGLE CHIP CPU
GND
VG 447
1.25BrR 543
7
1 2
9
6
CN.P8
1
GND
VG
WR 541
4
+
K8
M4
B 767
BEACON
3
4
VG
1 2
GND
5
WG 446
3
6
SDL
1.25W 321
WG
CN.35
WR 541 BrR 543
OW 546
GR 831
BEACON
91A
12
VY 440
2
SOFT/HARD
CN.P9
1.25W 320
BrG 441
4
1
5
WG
1 2 3
4
CONTROL 24V
3
VY
B 722
SOFT/HARD
SDL CN.P0
1.25LgR 350
BrG
WORK MODE
5
VY
RW 557
4
YR 830
WORK MODE
2
1.25LgR 540
0.85BG 660
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BrG
(SOFT/HARD)
CN.26
1 2 3 4 5 6
1.25RW 220
R 222
R 223
206,208,209
KEY SW.
F12
20A
BACK UP R 221
10A
F11
MAIN 20A
F1 0.85GR 231
0.85BrW 230
3
1.25R 206
M10
1.25G 020
1
1.25LgR 351
2
R 221
7
S5
10
2
2 3 5 4
-
1
G2
M8 1.25LgR 540
58Y
POWER 24V
5V
B+ TRAVEL MODE
R
1
M8 M10
REGULATOR
020,030
60R 001
60R 201
M10
IC
1.25LR 204 020,030
CN.A6
FILTER
1.25W 322
60R 200
1.25LgR 540
5R 002
1.25RW 202
1.25R 206
24V 50A
M5
1 2 3
A1
1
1.25WR 209
K7
RELAY BATTERY
ALTERNATOR E
5B 797
CN-A CN.S2
R
COMPUTER CN.5
HYDRAULIC FAN
1 2 3 4
(BLUE TAPE) 1.25GR 205
1 2
B+ TRAVEL MODE
2
WL 812 WV 813 OW 458 OG 459
1.25YR 208
F22
F27
1 2 3
S4 AUTO MODE
1.25W
IGN
CN-A CN.C2
CN-A
1.25W
CN-A CN.C3
CN.B4
1
IGN
1 2
CN-A
AMP 040 MULTI LOCK
K32
ILLUMINATION
S3 WORK MODE
1 2
CN-A CN.C4
CN.C1
CN.T3
TRAVEL MODE
CONTROL CONNECTOR
SDL
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
PWB
ADDITIONAL
1 2 3 4
S2
F25
M10
CN.28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PANEL;SWITCH (L)
1.25RY 225
812,813,458,459 645,745
MONITOR DISPLAY ASSY
P2
6
1.25R 206
592,593,598
CN.6
BrW 545
5
0.85BG 637
CN.5
2 4
1.25RY 225
P1
BrR 544
3
206,208,209
2LR 310
CIGAR LIGHTER CAB SEAT
F20
15A
LOCK LEVER (GATE) 1.25V 256
VR 240
10A
F4
ELEC.FUEL PUMP 20A
F8
AIR COND. FAN 0.85YW 270
BrW 260
10A
F5
AIR COND. COMPRESSOR
F14
5A
DC/DC CONVERTER
F17
VW 280
PW 255
0.85GW 290
1.25W 322
1.25W 325
10A
HORN CTWT REMOVAL
F19
15A
COMPUTER CONTROL 1.25W 320
LR 250
5A
F2
10A
F6
BEACON
ENGINE PRE-HEAT 30A
F9
1.25O 300
2WR 050
20A
F10 OPTION LINE
LUBRICATOR
FUEL FEED PUMP 30A
F7
1.25LW 340
2Gr 330
20A
F13 AIR COND.
COMPUTER POWER 20A
F3
1.25LgR 350
15A
F18 WIPER,WASHER
0.85VR 370
0.85B 704
0.85OR 375
0.85PG 598
PL 593
0.85RY 225
1.25R 206
1
1 2 58L CN.C5
1 2
CN.Z2
1.25WR 209
8R 207
1 2
58X
DEUTSCH HD14
P 592
J H
0.85BrR 360
G H J
B
1.25YR 208
1 2 58L
FUSE A (20A)
FUSE B (20A)
60A
F24
CN.C9
G
A B C D E F
C
0.85OR 385
D A
0.85BG 637
E F
15A
X3
15A
F16 LAMP(CAB)
X5
F15 LAMP (HOUSE,BOOM)
3R 213
58L
3R 211 3R 212
OPTIONAL POWER
F23
8R 207
2
8R 100
8R 207
R 225
F21
8R 207
CN.20
5R 210
1
1
EST CONNECTOR
A1 A2 A4 A6 A9 B1 B2 B3 B5 B6 B21 B22 B23
Y15
(RED TAPE)
FUSE 20A ; ENGINE CONTROLLER FUSE 5A ; COMPUTER CONTROL INSTRUMENT PANEL AND DIAGNOSTIC TEST SOCKET FUSE 20A ; COMPUTER POWER FUSE 10A ; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH FUSE 10A ; AIR CONDITIONER CONDENSER FAN FUSE 10A ; ROTARY LIGHT FUSE 30A ; FUEL FILLER PUMP FUSE 20A ; FUEL FEED PUMP FUSE 30A ; GLOW PLUG FUSE 20A ; LUBRICATOR (OPTION) CONNECTOR FUSE 10A ; BACK-UP FUSE 20A ; KEY SWITCH FUSE 20A ; HEATER / AIR CONDITIONER FUSE 5A ; AIR CONDITIONER COMPRESSOR FUSE 15A ; WORKING LIGHT (UPPERSTRUCTURE/ATTACHMENT) FUSE 15A ; WORKING LIGHT (CAB) AND OPTION CONNECTOR FUSE 10A ; DC-DC (24V-12V) CONVERTER FUSE 15A ; WIPER AND WASHER FUSE 15A ; HORN FUSE 15A ; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR ADJUSTMENT FUSE BOX FUSE 20A ; MAIN FUSE FOR F11 AND F12 CIRCUITS FUSE 65A ; MAIN FUSE FOR F3 TO F10 AND F13 TO F20 CIRCUITS FUSE 20A ; MAIN FUSE FOR F2 CIRCUIT FUSE 20A ; MAIN FUSE FOR F1CIRCUITS FUSE 60A ; SAFETY RELAY
Y7 Y8 Y9 Y12 Y13 Y14 Y15 Y31 Y32 Y33 Y34
COMPUTER ENGINE CONTROLLER WIPER CONTROLLER BLOWER CONTROLLER AIR CONDITIONER CONTROLLER COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EVA SENSOR AIR INTAKE TEMPERATURE SENSOR ENGINE OIL PRESSURE SWITCH SWING PILOT PRESSURE SWITCH BREAKER / CRUSHER PILOT PRESSURE SWITCH SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH BREAKER PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SWITCH (YELLOW BAND) TRAVEL PILOT PRESSURE SWITCH SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH PUMP PRESSURE SENSOR (P1) PRESSURE SENSOR (NEGA-CONT) PUMP PRESSURE SENSOR (P2) (BLUE BAND) OVERLOAD INDICATOR PRESSURE SWITCH (EUROPE) BOOST PRESSURE SENSOR AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR CRANKSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR BOOST TEMPERATURE SENSOR COMMON RAIL PRESSURE SENSOR EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR SUNLOAD SENSOR HORN REFUEL PUMP STOP ALARM WORKING LIGHT (UPPERSTRUCTURE) WORKING LIGHT (ATTACHMENT) WORKING LIGHT (CAB) CAB LIGHT CIGARETTE LIGHTER AIR CONDITIONER BATTERY ALTERNATOR AUDIBLE WARNING DEVICE TRAVEL ALARM RELAY-GLOW PLUG RELAY-HORN RELAY-ROTARY LIGHT RELAY-AIR CONDITIONER CONDENSER FAN RELAY BATTERY RELAY SAFETY RELAY-WORKING LIGHT (UPPERSTRUCTURE/ATTACHMENT) RELAY-WORKING LIGHT (CAB) BLOWER OFF RELAY REFUEL PUMP RELAY REFUEL PUMP STOP RELAY RELAY, HYDRAULIC FAN MAIN RELAY STARTER MOTOR WIPER MOTOR WASHER MOTOR MOTOR (AIR CHANGING) AIR VENT DIRECTION CONTROL MOTOR MOTOR ACT (AIR-MIX) BLOWER MOTOR AIR CONDITIONER CONDENSER FAN MOTOR FUEL FEED PUMP MOTOR EXHAUST GAS RECIRCULATION MOTOR ELECTRIC FUEL PUMP INSTRUMENT PANEL SWITCH PANEL (LEFT-HAND) SWITCH PANEL (RIGHT-HAND) MONITOR DISPLAY HOURMETER AIR CONDITIONER CONTROL PANEL GLOW PLUG THROTTLE VOLUME THERMISTOR INNER TEMPERATURE FUEL SENSOR KEY SWITCH TRAVEL MODE SWITCH WORK MODE SWITCH AUTO MODE SWITCH CUSHION CONTROL SWITCH ROTARY LIGHT SWITCH AUDIBLE ALARM CUT OUT SWITCH SWING BRAKE SWITCH ENGINE EMERGENCY STOP SWITCH WORKING LIGHT SWITCH WIPER SWITCH WASHER SWITCH OVERLOAD SWITCH BREAKER / CRUSHER SWITCH HORN SWITCH ONE TOUCH IDLE COUNTERWEIGHT REMOVAL MAIN SWITCH COUNTERWEIGHT RAISING/ LOWERING SWITCH COUNTERWEIGHT ARM RAISING/LOWERING SWITCH OPTIONAL SWITCH (RIGHT) OPTIONAL SWITCH (LEFT) HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH AIR CONDITIONING COMPRESSOR CLUTCH SWITCH DOOR LIMIT SWITCH FRONT WINDOW LIMIT SWITCH RESERVE TANK LOW SWITCH REFUEL PUMP SWITCH AIR CLEANER SENSOR DOUBLE ACTING SWITCH (OPTIONAL) COOLING HYDRAULIC MOTOR SWITCH DC-DC (24V-12V) CONVERTER ANTENNA ROTARY LIGHT CONNECTOR OPTIONAL POWER CONNECTOR ENGINE TEST POINT CONNECTOR CONTROLLER TEST POINT CONNECTOR CAB SEATCOMPRESSOR MOTOR CONNECTOR LUBRICATOR CONNECTOR RADIO CONNECTOR ANTI-THEFT SYSTEM CONNECTOR ACCESSORY SOCKET CLEAR MEMORY 1 CLEAR MEMORY 2 SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND) PILOT PRESSURE SOLENOID VALVE (BLUE BAND) SWING BRAKE SOLENOID VALVE (PINK BAND) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) POWER-UP SOLENOID VALVE (YELLOW BAND) CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND) MAIN PUMP PROPORTIONAL SOLENOID AIR CONDITIONER MAGNET CLUTCH CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE COUNTERWEIGHT RAISING SOLENOID VALVE COUNTERWEIGHT LOWERING SOLENOID VALVE COUNTERWEIGHT ARM RAISING SOLENOID VALVE COUNTERWEIGHT ARM LOWERING SOLENOID VALVE COOLING HYDRAULIC MOTOR SOLENOID VALVE PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC MOTOR SUPPLY PUMP VALVE (PCV1) SUPPLY PUMP VALVE (PCV2)
CN. A1
TABLE OF COLOR SYMBOLS
5B 796
M6 FLOOR
M6 PLATFORM
SYMBOL
COLOR
SYMBOL
COLOR
B
BLACK
R
RED
W
WHITE
Y
YELLOW
Br
BROWN
Lg
LIGHT GREEN
P
PINK
Sb
SKY BLUE
V
VIOLET
L
BLUE
G
GREEN
Gr
GRAY
O
ORANGE
NOTE : "BR" INDICATES BLACK CABLE WITH RED STRIPE.
LEGENDE CONNECTED
NOT CONNECTED CONNECTOR (MALE)
BOOT GROUND
CABLE GROUND
SINGLE WIRE CONNECTOR
HARNESS
INSULATION AGAINST MAGNETISM
CN.
CONNECTOR NUMBER
SWP
CONNECTOR'S NAME
CONNECTOR (FEMALE)
60 B 001 CIRCUIT NUMBER COLOR AREA
CX460 EXCAVATOR ELECTRICAL SCHEMATIC - 87574470A
